D 1501 Service Manual

Develop

1158SBG000BA

CONTENTS
GENERAL
1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-1 2. PRECAUTIONS FOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . G-4 3. PRECAUTIONS FOR USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-5 4. HANDLING OF THE CONSUMABLES . . . . . . . . . . . . . . . . . . . . . . . . . G-6 5. SYSTEM OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-7

1158SBM000BA

MECHANICAL/ELECTRICAL
1. CROSS-SECTIONAL VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-1 2. COPY PROCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-2 3. DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-4 4. SEQUENTIAL EXPLANATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-5 5. PC DRUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-10 6. IMAGING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-11 6-1. Imaging Unit Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-12 6-2. Toner Recycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-13 6-3. I/U Fuse F4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-13 7. DEVELOPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-14 7-1. ATDC Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-15 7-2. Magnet Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-17 7-3. Developing Bias . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-18 7-4. Doctor Blade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-19 7-5. Magnet Roller Lower Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-19 8. CLEANING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-20 8-1. Cleaning Bias . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-21 9. TONER HOPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-22 9-1. Toner Hopper Locking/Unlocking . . . . . . . . . . . . . . . . . . . . . . . . . . M-22 9-2. Toner Replenishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-22 9-3. Shutter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-23 9-4. Toner Hopper Home Position Detection . . . . . . . . . . . . . . . . . . . . M-23 9-5. Toner Bottle Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-24 9-6. Toner Replenishing Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-25

CONTENTS
10. DRUM CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-26 11. IMAGE ERASE LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-27 12. OPTICAL SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-30 12-1. Exposure Lamp LA1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-31 12-2. AE Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-32 12-3. Lamp Reflectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-33 12-4. Aperture Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-33 12-5. 1st/2nd Scanner Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-34 12-6. 4th Mirror Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-36 12-7. Lens Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-37 13. 14. MAIN ERASE LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-38 15. IMAGE TRANSFER AND PAPER SEPARATION . . . . . . . . . . . . . . . . M-39 16. PAPER SEPARATOR FINGERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-41 17. PAPER TAKE-UP/FEED SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-43 17-1. Edge Guide and Trailing Edge Stop . . . . . . . . . . . . . . . . . . . . . . M-44 17-2. Drawer Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-45 17-3. Paper Lifting Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-45 17-4. Drawer-in-Position Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-46 17-5. Universal Tray Paper Size Detection . . . . . . . . . . . . . . . . . . . . . M-47 17-6. Paper Empty Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-48 17-7. Paper Separating Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . M-49 17-8. Paper Take-Up Roll . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-50 17-9. Paper Take-Up Retry Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-51 18. VERTICAL PAPER TRANSPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-52 19. SYNCHRONIZING ROLLERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-53 19-1. Upper Synchronizing Roller Positioning . . . . . . . . . . . . . . . . . . . M-54 19-2. Paper Dust Remover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-54 19-3. Synchronizing Roller Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-55 20. PAPER TRANSPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-56 21. FUSING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-57 21-1. Fusing Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-58 21-2. Fusing Rollers Pressure Mechanism . . . . . . . . . . . . . . . . . . . . . M-59 21-3. Oil Roller/Cleaning Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-59 22. EXIT UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-60 22-1. Upper/Lower Separator Fingers . . . . . . . . . . . . . . . . . . . . . . . . . M-60 22-2. Paper Exit Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-61

ii

CONTENTS
23. 24. DEHUMIDIFYING SWITCH (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . M-62 25. MULTI BYPASS TABLE MB-4 (OPTION) . . . . . . . . . . . . . . . . . . . . . . . M-63 25-1. Paper Take-Up Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-64 25-2. Paper Separating Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . M-66 25-3. Paper Empty Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-67 26. 27. COOLING FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-68 28. OPTICAL SECTION COOLING FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . M-69 29. MEMORY BACKUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-70

iii

1151SBG000D

SAFETY INFORMATION
ALL Areas CAUTION Danger of explosion if battery is incorrectly replaced. Replace only with the same or equivalent type recommended by the manufacturer. Dispose of used batteries according to the manufacturers instructions. Denmark ADVARSEL! Lithiumbatteri - Eksplosionsfare ved fejlagtig hndtering. Udskiftning m kun ske med batteri af samme fabrikat og type. Levr det brugte batteri tilbage til leverandren. Norway ADVARSEL Eksplosjonsfare ved feilaktig skifte av batteri. Benytt samme batteritype eller en tilsvarende type anbefalt av apparatfabrikanten. Brukte batterier kasseres i henhold til fabrikantens instruksjoner. Sweden VARNING Explosionsfara vid felaktigt batteribyte. Anvnd samma batterityp eller en ekvivalent typ som rekommenderas av apparattillverkaren. Kassera anvnt batteri enligt fabrikantens instruktion. Finland VAROITUS Paristo voi rjht, jos se on virheellisesti asennettu. Vaihda paristo ainoastaan laitevalmistajan suosittelemaan tyyppiin. Hvit Kytetty paristo valmistajan ohjeiden mukaisesti.

1151SBG000CA

GENERAL

1158SBG0100A

1 SPECIFICATIONS
TYPE PHOTOCONDUCTOR COPYING SYSTEM PAPER FEEDING SYSTEM EXPOSURE SYSTEM DEVELOPING SYSTEM CHARGING SYSTEM IMAGE TRANSFER SYSTEM PAPER SEPARATING SYSTEM FUSING SYSTEM PAPER DISCHARGING SYSTEM MAXIMUM ORIGINAL SIZE COPY MEDIUM
Paper Drawer (Automatic feeding) Plain paper (60 to 90 g/m2) Medium Translucent paper Transparencies Thick paper (91 to 157 g/m2) Recycled paper Dimens sions Maximum (Width  Length) Minimum (Width  Length) f f 297  432 mm Manual Bypass (Single-sheet feeding) f f f f f 297  432 mm

: Desktop (with Stationary Platen) : Organic Photoconductor : Electrostatic Dry Powdered Image Transfer to Plain Paper : 2-Way Feeding Paper Drawer: Universal Tray (250 sheets of paper) Manual Bypass Table

: Mirror Scanning, Slit Exposure : Minolta New Micro-Toning System : Comb Electrode DC Negative Corona with Scorotron System : Visible Image Transfer by means of a Single-Wire DC Negative Corona with Corotron System : Single-Wire AC Corona with Corotron System, plus Paper Separator Finger : Heat Roller : Charge Neutralizing Brush

: Metric-A3L; Inch-11

17L (L: Lengthwise)

140  182 mm

100  140 mm

f: Permissible

X: Not permissible

G-1

MULTIPLE COPIES WARMING-UP TIME FIRST COPY TIME

: 1 to 99 : 30 sec. or less with room temperature of 20C and rated power voltage : A4C or 8-1/2  11C: 7.2 sec. or less (in Full size Mode using 1st Drawer)

CONTINUOUS COPY SPEED (copies/min.): Fed from Drawer

Zoom Ratio Area Size A3L A4L A4C B4L 1.00 12 15 15 13 Zoom Ratio Area Size 11 17 (L) 8-1/2 11 (L) 8-1/2 11 (C) 5-1/2 8-1/2 (L) 1.00 11 15 15 15

Metric

Inch

L: Lengthwise; C: Crosswise
ZOOM RATIOS
Area Mode Full Size Fixed Reduction Europe (Metric) 100% 81% 70% 50% 115% 141% 200% Taiwan (Metric) 100% 81% 70% 50% 122% 141% 200% Inch 100% 78% 64% 50% 121% 129% 200%

Enlargement Variable

50% to 200% (in 1% increments)

LENS EXPOSURE LAMP FUSING TEMPERATURE

: Through Lens (F = 8.0, f = 180 mm) : Halogen Frost Tube Lamp : 195C

G-2

POWER/CURRENT CONSUMPTION (Copier Only)

Exposure Lamp (Rating) Fusing Heater Lamp (Rating) 115/120 V 900 W 115/120 V 900 W 220/240 V 900 W Max. Power Consumption 1180 W 1220 W 1290 W 1195 W 1270 W Max. Current Consumption 10.4 A 10.4 A 5.6 A

Voltage

In Standby

115 V 120 V 127 V 220 V 240 V

935 W 965 W 1070 W 930 W 1060 W

80 V 225 W

160 V 240 W

POWER REQUIREMENTS

: 115 V, 120 V, 127 V, 220 V, 240 V; 50/60 Hz

ENVIRONMENTAL CONDITIONS
Temperature Humidity Ambient Illumination Levelness 10 to 30C with a fluctuation of 10C or less per hour 15 to 85% RH with a fluctuation of 10% RH or less per hour 3,000 lux or less 1(1.75 mm/100 mm)

DIMENSIONS (Copier Only) WEIGHT STANDARD ACCESSORIES

: Width .... 610 mm Depth .... 632.5 mm Height ... 401 mm (including Original Cover) : 51 kg (excluding the Manual Bypass Table, starter, toner, and paper) : Operators Manual*1, Setting-up Instructions, Starter*2, Copy Tray, Manual Bypass Table, Auxiliary Cap *1: Except Europe and Taiwan *2: Europe only

G-3

1151SBG0200A

2 PRECAUTIONS FOR INSTALLATION

J Installation Site
To ensure safety and utmost performance of the copier, the copier should NOT be used in a place: F Where it will be subject to extremely high or low temperature or humidity. F Which is exposed to direct sunlight. F Which is in the direct air stream of an air conditioner, heater or ventilator. F Which puts the operator in the direct stream of exhaust from the copier. F Which has poor ventilation. F Where ammonia gas might be generated. F Which does not have a stable, level floor. F Where it will be subject to sudden fluctuations in either temperature or humidity. If a cold room is quickly heated, condensation forms inside the copier, resulting in blank spots in the copy. F Which is near any kind of heating device. F Where it may be splashed with water. F Which is dirty or where it will receive undue vibration. F Which is near volatile flammables or curtains.

J Power Source
Use an outlet with a capacity of 115/120/127V, 13.2A or more, or 200/220/240V, 8.1A or more. F If any other electrical equipment is sourced from the same power outlet, make sure that the capacity of the outlet is not exceeded. F Use a power source with little voltage fluctuation. F Never connect by means of a multiple socket any other appliances or machines to the outlet being used for the copier. F Make the following checks at frequent intervals: D Is the power plug abnormally hot? D Are there any cracks or scrapes in the cord? D Has the power plug been inserted fully into the outlet? D Does something, including the copier itself, ride on the power cord? F Ensure that the copier does not ride on the power cord or communications cable of other electrical equipment, and that it does not become wedged into or underneath the mechanism.

J Grounding
To prevent receiving electrical shocks in the case of electrical leakage, always ground the copier. F Connect the grounding wire to: D The ground terminal of the outlet. D A grounding contact which complies with the local electrical standards. F Never connect the grounding wire to a gas pipe, the grounding wire for a telephone, or a water pipe.

G-4

1151SBG0300A

3 PRECAUTIONS FOR USE

To ensure that the copier is used in an optimum condition, observe the following precautions. F Never place a heavy object on the copier or subject the copier to shocks. F Insert the power plug all the way into the outlet. F Do not attempt to remove any panel or cover which is secured while the copier is making copies. F Do not turn OFF the Power Switch while the copier is making copies. F Provide good ventilation when making a large number of copies continuously. F Never use flammable sprays near the copier. F If the copier becomes inordinately hot or produces abnormal noise, turn it OFF and unplug it. F Do not turn ON the Power Switch at the same time when you plug the power cord into the outlet. F When unplugging the power cord, do not pull on the cord; hold the plug and pull it out. F Do not bring any magnetized object near the copier. F Do not place a vase or vessel containing water on the copier. F Be sure to turn OFF the Power Switch at the end of the workday or upon power failure. F Use care not to drop paper clips, staples, or other small pieces of metal into the copier.

J Operating Environment
The operating environmental requirements of the copier are as follows. D Temperature: 10C to 30C with a fluctuation of 10C per hour D Humidity: 15% to 85% RH with a fluctuation of 10% RH per hour

J Power Requirements
The power source voltage requirements are as follows. D Voltage Fluctuation: AC115/120/127/220/240V "10% (Copying performance assured) +6%, 10% (Only AC127V) 15% (Paper feeding performance assured) D Frequency Fluctuation: 50/60 Hz "0.3%

G-5

1151SBG0400A

4 HANDLING OF THE CONSUMABLES

Before using any consumables, always read the label on its container carefully. F Use the right toner. The applicable copier model name is indicated on the Toner Bottle. F Paper is apt to be easily damaged by dampness. To prevent absorption of moisture, store paper, which has been removed from its wrapper but not loaded into the Drawer, in a sealed plastic bag in a cool, dark place. F Keep consumables out of the reach of children. F Do not touch the PC Drum with bare hands. F Store the paper, toner, and other consumables in a place free from direct sunlight and away from any heating apparatus. F The same sized paper is of two kinds, short grain and long grain. Short grain paper should only be fed through the copier crosswise, long grain paper should only be fed lengthwise. F If your hands become soiled with toner, wash them with soap and water immediately. F Do not throw away any used consumables (PC Drum, starter, toner, etc.). They are to be collected. NOTE Do not burn, bury in the ground, or throw into the water any consumables (PC Drum, starter, toner, etc.).

G-6

1158SBG0500A

5 SYSTEM OPTION

1142O010AA

1.

Multi Bypass Table MB-4

G-7

1151SBM000CA

MECHANICAL/ ELECTRICAL

1158SBM0100A

1 CROSS-SECTIONAL VIEW
2 3 4 5 6 7 8 9 10

1 11 12 13

22 21 20

14 15

19

18

17

16

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

3rd Mirror 2nd Mirror 1st Mirror Exposure Lamp LA1 Lamp Reflector Lens Cleaning Blade PC Drum Charge Corona Image Erase Lamp LA3 4th Mirror PC Drum Sleeve/Magnet Roller

13. 14. 15. 16. 17. 18. 19. 20. 21. 22.

Synchronizing Roller Transport Roller Paper Take-Up Roll Drawer Image Transfer/Paper Separator Coronas Suction Unit Cleaning Roller Oil Roller Upper/Lower Fusing Roller Paper Exit Roller

M-1

1158SBM0200A

2 COPY PROCESS
2 3 4 10 9 1 5

13
1. 2. 3. 4. 5. 6. 7. PC DRUM DRUM CHARGING IMAGE ERASE EXPOSURE DEVELOPING PAPER FEEDING IMAGE TRANSFER

12

11
8. 9. 10. 11. 12. 13.

8
PAPER SEPARATION CLEANING MAIN ERASE TRANSPORT FUSING PAPER EXIT

MANUAL BYPASS TABLE

1. PC Drum
The PC Drum is an aluminum cylinder coated with a photosensitive semiconductor. It is used as the medium on which a visible developed image of the original is formed. (For more details, see p. M-10.)

2. Drum Charging
The PC Drum Charge Corona Unit is equipped with a Comb Electrode and a Scorotron Grid to deposit a uniform negative charge across the entire surface of the PC Drum. (For more details, see p. M-26.)

3. Image Erase
Any areas of charge which are not to be developed are neutralized by lighting up LEDs. (For more details, see p. M-27.)

4. Exposure
Light from the Exposure Lamp reflected off the original is guided to the surface of the PC Drum and reduces the level of the negative charges, thereby forming an electrostatic latent image. (For more details, see p. M-30.)

5. Developing
Toner positively charged in the Developer Mixing Chamber is attracted onto the electrostatic latent image changing it to a visible, developed image. A DC negative bias voltage is applied to the Sleeve/Magnet Roller to prevent toner from being attracted onto those areas of the PC Drum which correspond to the background areas of the original. (For more details, see p. M-14.)

M-2

6. Paper Feeding
Paper is fed either automatically from the 1st or 2nd Drawer, or manually via the Manual Bypass Table. The Drawer has fingers that function to separate the top sheet of paper from the rest at take-up. (For more details, see p. M-43.)

7. Image Transfer
The single-wire Image Transfer Corona Unit applies a DC negative corona emission to the underside of the paper, thereby attracting toner onto the surface of the paper. (For more details, see p. M-39.)

8. Paper Separation
The single-wire Paper Separator Corona Unit applies an AC corona emission to the underside of the paper to neutralize the paper. In addition, mechanical paper separation is provided by the two PC Drum Paper Separator Fingers fitted to the Imaging Unit. (For more details, see p. M-39)

9. Cleaning
Residual toner on the surface of the PC Drum is scraped off by the Cleaning Blade. (For more details, see p. M-20.)

10. Main Erase

Light from the Main Erase Lamp neutralizes any surface potential remaining on the surface of the PC Drum after cleaning. (For more details, see p. M-38.)

11. Transport
The paper is fed to the Fusing Unit by the Suction Belts. (For more details, see p. M-56.)

12. Fusing
The developed image is permanently fused to the paper by a combination of heat and pressure applied by the Upper and Lower Fusing Rollers. (For more details, see p. M-57.)

13. Paper Exit

After the fusing process the paper is fed out by the Paper Exit Roller onto the Copy Tray. (For more details, see p. M-60.)

M-3

1158SBM0300A

DRIVE SYSTEM

This copier is equipped with two main drive motors, PC Drive Motor M1 that drives the upper half of the copier (Imaging Unit) and Main Drive Motor M2 which gives drive for the lower half of the copier (paper take-up/feeding and transport mechanism and Fusing Unit). Each has its own drive transmitting gears and timing belts as illustrated below. Drive Train for Lower Half of Copier
Paper Exit Roller Drive Suction Unit Drive Upper Fusing Roller Drive

Main Drive Motor M2 Synchronizing Roller Clutch CL 1 Coupled to Paper Take-Up Unit Paper Transport Clutch CL 2

Drive Train for Upper Half of Copier

PC Drum Drive

Imaging Unit Drive

Drive Train for Paper Take-Up Unit

Coupled to Copier Gear

PC Drive Motor M1

Vertical Transport Roller

Paper Drawer Paper Take-Up Roll

1142M002AA

M-4

1158SBM0400A

4 SEQUENTIAL EXPLANATION
*Numbers given in rectangles
A

in the following flowchart are timer values in sec.

The power cord is plugged into the outlet.

Power cord is plugged in. ON ON ON DC24V for Drum heating (PU2) Drum Dehumidifying Heater H2 Paper Dehumidifying Heater H3 Only when Serviceman Switch S3 is ON

Power Switch S1 is turned ON.

S1 ON OFF ON ON ON ON H2 DC5V (PWB-C) DC24V (PU2) Control panel The Cooling Fan turns at full speed. Approx. 3 Approx. 0.5 ON ON ON The Cooling Fan turns at half speed. Fusing Heater Lamp H1

Scanner Reference Position Sensor PC81 *If the Scanner is not at the home position, Scanner Motor M5 is energized to move the Scanner to the home position. ON Lens Reference Position Sensor PC90 *If the Lens is not at the home position, Lens Motor M6 is energized to move the Lens to the home position. ON Mirror Reference Position Sensor PC86 *If the 4th Mirror is not at the home position, Mirror Motor M7 is energized to move the Mirror to the home position.

Starter setup and ATDC Sensor automatic adjustment *Only when the Imaging Unit is new. I/U Fuse F4 blows when the starter setup sequence is completed normally.

M-5

The Fusing Unit temperature reaches 205C.

Fusing Thermistor TH1 detects 205C. ON/OFF Fusing Heater Lamp H1 *The Fusing Unit temperature control is started.

M-6

D The Start Key is pressed.

Start Key ON ON ON ON ON ON ON ON PC Drive Motor M1 Main Erase Lamp LA2 Main Drive Motor M2 Image Erase Lamp LA3 *All LEDs are turned ON. Developing Bias (High Voltage Unit HV1) Paper Separator Corona (HV1) Cleaning Bias (HV1) *Some models have no Bias Seal installed depending on their marketing areas. Synchronizing Roller (CL1) *For approx 0.2 sec only Approx. 0.3 ON Paper Take-Up Roll (Solenoid SL2) Approx. 0.1 Approx. 0.2 Approx. 0.2 Approx. 2.5
E Paper is taken up.

ON

OFF

SL2

ON ON ON

PC Drum Charge Corona/Image Transfer Corona (HV1) Transport Roller (Paper Transport Clutch CL2) Synchronizing Roller (CL1)

Paper Take-Up Solenoid SL2 ON Approx. 0.4 ON Drawer Paper Take-Up Sensor PC55 Approx. 0.7 ON Transport Roller Sensor PC51

Approx. ON 0.5

Paper Leading Edge Detecting Sensor PC54 Approx. OFF Paper 0.2 Transport Clutch CL2 Approx. ON Exposure Lamp LA1 0.2

M-7

 Approx. 0.6 ON OFF Scanner Motor M5 Scanner Reference Position Sensor PC81 Image Erase Lamp LA3 LEDs ON/OFF control is started. Synchronizing Roller Clutch Approx. ON 0.2 ON CL1 CL2 Separator Fingers (Separator Solenoid SL1) SL1 Approx. OFF 0.4
F A scan motion is completed.

Approx. 0.3

Approx. ON 0.4

SCEND signal: LOW Approx. ON 0.2 Approx. 0.3 All LEDs of Unexposed Areas/Edge Erase Lamp LA3 ON Scanner starts return motion. Approx. 0.6 ON Scanner Reference Position Sensor PC81

*For A4 crosswise, 1.000 Approx. OFF 0.3 Exposure Lamp LA1

M-8

G The last paper moves past Transport Roller Sensor PC51.

PC51 OFF Approx. 0.6 OFF

Paper Leading Edge Detecting Sensor PC54 OFF Synchronizing Roller (Synchronizing Roller Clutch CL1) PC Drum Charge Corona/Image Transfer Corona (High Voltage Unit HV1) OFF OFF OFF OFF OFF PC Drive Motor M1 Main Erase Lamp LA2 Unexposed Areas/Edge Erase Lamp LA3

Approx. 0.4 Approx. 0.7

OFF

Approx. 0.7

Approx. 0.5

Developing Bias (HV1) Cleaning Bias (HV1) *Some models have no Bias Seal installed depending on their marketing areas. Paper Separator Corona (HV1)

OFF Approx. 1.2 Approx. 2.6

H

OFF ON

Transport Roller (CL2) Paper Exit Sensor PC53

The paper moves past Paper Exit Sensor PC53.

PC53 OFF Approx. OFF 2.3 Main Drive Motor M2

M-9

1151SBM0500A

5 PC DRUM
The photoconductive drum used in this copier is the organic photoconductor (OPC) type. The drum is made up of two distinct, semiconductive materials on an aluminum alloy base. The outer of the two layers is called the Charge Transport Layer (CTL), while the inner layer is called the Charge Generating Layer (CGL). The PC Drum has its grounding point inside at its rear end. When the Imaging Unit is installed in the copier, the shaft on which the PC Drum Drive Coupling Gear is mounted contacts this grounding point. Handling Precautions This photoconductor exhibits greatest light fatigue after being exposed to light over an extended period of time. It must therefore be protected from light by a clean, soft cloth whenever the Imaging Unit has been removed from the copier. Further, use utmost care when handling the PC Drum to prevent it from being contaminated.
PC Drum Cross-Sectional View PC Drum CTL CGL Aluminum Cylinder

Gear

Shaft

Grounding Point

Grounding Plate

PC Drum Drive Coupling Gear

M-10

1139SBM0600A

6 IMAGING UNIT
This copier is equipped with an Imaging Unit, or IU, which integrates a PC Drum, PC Drum Charge Corona, Developing Unit, Cleaning Unit, and Toner Recycling mechanism into one assembly. The Unit also includes the Upper Synchronizing Roller which facilitates clearing of a paper misfeed.

Corona Unit Cleaning Lever

PC Drum Charge Corona PC Drum

Coupled to Gear in Copier

Developer Mixing Chamber Counter Toner Supply Port

Paper Separator Fingers

Upper Synchronizing Roller

Paper Guide Plate

M-11

1139SBM0601A

6-1. Imaging Unit Drive Drive for the Imaging Unit is transmitted by one of the gears on the Unit. This particular gear is in mesh with the Imaging Unit Drive Gear in the copier.

Developer Mixing Screw Drive Gear

Bucket Roller Drive Gear Imaging Unit Drive Gear (in Copier) Sleeve/Magnet Roller Drive Gear

Toner Recycling Coil Drive Gears Coupling (in Copier)

M-12

1151SBM0602A

6-2. Toner Recycling The copier is provided with a toner recycling mechanism. The toner, which has been scraped off the surface of the PC Drum by the Cleaning Blade and collected in the Cleaning Unit, is conveyed by the two Toner Recycling Coils to the Toner Supply Port and, from there, it is returned back to the Developer Mixing Chamber of the Developing Unit. One of the gears of the Toner Recycling mechanism receives drive through a gear at the rear end of the PC Drum.

Toner Supply Port

Toner Recycling Path

Toner Recycling Coil

Bevel Gears

Toner Recycling Coil

1151SBM0603A

6-3. I/U Fuse F4 The Imaging Unit is provided with a fuse called I/U Fuse F4. When a new Imaging Unit is installed in the copier and the Power Switch turned ON, an I/U Set signal is output causing the copier to start the starter setup sequence and ATDC Sensor automatic adjustment. When the starter setup sequence is completed normally, an I/U Fuse Blow signal is output to blow F4. Once F4 is blown, the I/U Set signals are no longer output. This means that the starter setup sequence and ATDC Sensor automatic adjustment will not be carried out when the Power Switch is thereafter turned ON.
Control Signal F4 PWB-A PJ1A-6 When Fuse is not Blown H When Fuse is Blown L WIRING DIAGRAM 30-B

M-13

1151SBM0700A

7 DEVELOPMENT
The Developing Unit built into the Imaging Unit performs the following functions: D Mixes the toner and carrier well to ensure that a sufficient amount of toner is positively charged. D Detects the toner-to-carrier ratio of the developer by means of the ATDC Sensor and replenishes the supply of toner as necessary. D Detects a toner empty condition by means of the ATDC Sensor. D Ensures that a proper amount of toner is attracted to the PC Drum by means of its Sleeve/Magnet Roller, Developing Bias, and Doctor Blade.

PC Drum Developer Mixing Screw Doctor Blade

Sleeve/Magnet Roller

Bucket Roller

ATDC Sensor

M-14

1151SBM0701A

7-1. ATDC Sensor ATDC Sensor UN3 installed on the underside of the Developer Mixing Chamber detects the varying toner-to-carrier ratio of the developer which flows over it in the Chamber. The copier CPU compares the detected ratio with the ratio set by the ATDC Detection Level Mode (Tech. Rep. Choice SCH-90) to control toner replenishment.
Set T/C (%) 4.0 4.5 5.0 5.5 6.0 6.5 7.0 ATDC Output Voltage (V) 2.692 2.596 2.5 (Standard) 2.404 2.308 2.212 2.116

Toner is replenished for 5 seconds (the Toner Bottle is turned one turn, which is equivalent to a run of 2 copy cycles) for each Toner Replenishing signal. If the toner-to-carrier ratio becomes lower than 2.5%, the copier inhibits the initiation of a new copy cycle (this feature can be enabled or disabled by a Tech. Rep. Choice mode). When a ratio of 3% or more is recovered as a result of Auxiliary Toner Replenishing, the copier permits the initiation of a new copy cycle. If the Front Door is swung open and closed with a T/C ratio of less than 3%, the copier initiates an Auxiliary Toner Replenishing sequence. (It stops the sequence as soon as a T/C ratio of 3.5% is reached.) ATDC Sensor Automatic Adjustment An automatic adjustment of the ATDC Sensor is made in the F8 Test Mode operation and when a new Imaging Unit is installed in the copier. *When a New Imaging Unit is Installed in the Copier: Following the execution of the starter setup mode upon power-up, the copier CPU reads the output value of the ATDC Sensor and establishes the reading as the reference value. *When F8 is Run after Starter Has Been Changed: Following the execution of the starter setup mode upon pressing of the Start Key, the copier CPU reads the output value of the ATDC Sensor and establishes the reading as the reference value. NOTE: If an F8 operation is run at a time when the starter has not been changed, it can result in a wrong T/C reference value being set by the copier. Avoid casual use of F8. If the setting value has been cleared because of the RAM Board being replaced, however, enter the ATDC control value before the replacement using the Zoom Up/Down Keys in the F8 operation (without pressing the Start Key).

M-15

Toner Empty Detection The copier has no toner empty detecting sensor and, instead, the ATDC Sensor performs that function. The ATDC Sensor checks the toner-to-carrier ratio and, if it reads a T/C ratio lower than the set level for 37 copies and, further, if it next reads a ratio 1% lower than the setting, this is a toner-empty condition. The toner-empty condition is canceled after detection under any of the following conditions: D The set T/C ratio has been recovered. D After the Front Door has been swung open and closed.
Standard Output Voltage 2.692 2.596 2.5 2.404 2.308 2.212 2.116 30-B

Control Signal

Set T/C 4.0% 4.5% 5.0%

WIRING DIAGRAM

UN3

PWB-A PJ1A-3

5.5% 6.0% 6.5% 7.0%

M-16

1151SBM0702A

7-2. Magnet Roller The Magnet Roller of the Sleeve/Magnet Roller of this copier has the following magnetic characteristics. Part of pole S2 before the principal N1 pole (i.e., the area marked as S2b in the Fig. below) provides a very weak magnetic force. If developer is compacted and clogs at the Doctor Blade and, as a result, part of the surface of the Sleeve/Magnet Roller is not covered with developer, the nearby developer around S2b goes to those uncovered areas because of its weak magnetic force. This helps prevent blank lines from occurring on the copy. The Sleeve Roller, onto which developer is attracted by the magnetic fields of force set up by the poles of the Magnet Roller, turns to convey the developer toward the point of development. It also means that the developer fresh from the Developer Mixing Chamber is always brought to the point of development. As we noted earlier, the Imaging Unit integrates the Developing Unit with the PC Drum into one body. Because of that, it is impossible to move the Developing Unit against the PC Drum, thereby providing a certain distance between the PC Drum and Sleeve/Magnet Roller. The Magnet Roller has therefore been made movable: the Bushing is pressed by compression springs thereby pressing the Positioning Collars on both ends of the Magnet Roller against the PC Drum. This ensures a given distance between the PC Drum and the Sleeve/Magnet Roller.
Magnetic Pole Positioning

Pole Having Weak Magnetic Force

Movable Bushing

Compression Spring

Fixed Bushing PC Drum

M-17

1151SBM0703A

7-3. Developing Bias A negative voltage (Vb = Developing Bias voltage) is applied to the Sleeve Roller to prevent a foggy background on the copy. The amount of toner attracted onto the surface of the PC Drum depends on how much lower the PC Drum surface potential (Vi) is than Vb (i.e., the potential difference). D When the potential difference is large, a greater amount of toner is attracted. D When the potential difference is small, a smaller amount of toner is attracted. Because the Magnet Roller of this copier is movable, a flat spring is used as the Bias Terminal which follows the movement of the Magnet Roller.

Bias Terminal Magnet Roller

Control Signal Developing Bias PWB-A PJ12A-4

ON L

OFF H

WIRING DIAGRAM 30-A

M-18

1151SBM0704A

7-4. Doctor Blade The Doctor Blade installed over the Sleeve/Magnet Roller regulates the height of the developer brush on the surface of the Sleeve Roller. The Blade is perpendicular to the direction of movement of the Magnet Roller to minimize variations in the distance between the Doctor Blade and Magnet Roller as the Magnet Roller moves.
Doctor Blade

Direction of Magnet Roller Movement

Magnet Roller

1139SBM0705A

7-5. Magnet Roller Lower Filter *Except the U.S.A., Canada, and Europe There is a slit provided under the Magnet Roller to collect insufficiently charged toner in the grounded Toner Antispill Receiver. This effectively prevents the toner from spilling onto the mechanisms inside the copier.

Magnet Roller

Slit

M-19

1139SBM0800A

8 CLEANING UNIT
The Cleaning Blade is pressed tightly against the surface of the PC Drum and scrapes off any toner remaining on the surface after image transfer and paper separation have been completed. The Cleaning Blade is moved back and forth to prevent the PC Drum from deteriorating and the Cleaning Blade from warping away from the surface of the PC Drum. There is a Toner Antispill Mylar affixed to the Imaging Unit. It prevents toner scraped off the surface of the PC Drum from falling down onto the surface of the copy paper or the paper path. In addition, a Side Seal and Brush Seal are affixed to both ends of the Imaging Unit on both sides of the Cleaning Blade. They prevent toner from spilling from both ends of the Cleaning Blade.
Cleaning Blade Tension Spring Brush Seal

Side Seal

Toner Antispill Mylar

Blade Lateral Movement Cam

M-20

1151SBM0801A

8-1. Cleaning Bias *Except the U.S.A., Canada, and Europe There is a Cleaning Bias Seal installed to minimize damage to the PC Drum from acid paper.
Toner Antispill Mylar

PC Drum

Cleaning Bias Seal

Control Signal Cleaning Bias PWB-A PJ12A-4

ON L

OFF H

WIRING DIAGRAM 31-C

M-21

1151SBM0900A

9 TONER HOPPER
1139SBM0901A

9-1. Toner Hopper Locking/Unlocking The Toner Hopper is not integrated into the Imaging Unit; instead, it is secured to the copier. To replace an empty Toner Bottle, the user first needs to swing the Toner Bottle Holder out 40 to the front. The Holder pivots about the Toner Supply Port as it is swung out or in, which effectively prevents toner from spilling when the Holder is swung out or in.
Copier Frame Lock

Toner Replenishing Motor M8 Toner Supply Port 40

Toner Bottle
1151SBM0902A

Toner Bottle Holder

9-2. Toner Replenishing

D Drive from Toner Replenishing Motor M8 is transmitted via the motor shaft to the Bottle Cap Claw, which turns the Toner Bottle. As the Toner Bottle is fitted to the Coupling, both turn together during toner replenishing. D There is a Metering Chamber provided at the toner supply port of the Coupling. It functions to regulates the amount of toner that falls through the port. D There is a supply port for the exclusive use of the starter. The starter does not pass through the Metering Chamber, which means that it takes a shorter time to charge the starter.
Metering Chamber Starter Supply Port Coupling

Opening

Bottle Cap Claw

1151M018YA

Toner Replenishing Motor M8

M-22

1151SBM0903A

9-3. Shutter The connection between the Toner Hopper and Imaging Unit is provided with a Shutter which prevents toner from spilling when the Imaging Unit is slid out of the copier.
Imaging Unit Out of Copier Imaging Unit in Position in Copier

Shutter

Imaging Unit

1151SBM0904A

9-4. Toner Hopper Home Position Detection Coupling is fitted with a Home Position Plate which is detected by Toner Hopper Home Position Sensor PC112. This ensures that the Toner Bottle is located so that its opening is positioned on top whenever M8 is deenergized.

Toner Replenishing Motor M8

Home Position Plate

1151M019AA

Toner Hopper Home Position Sensor PC112

M-23

1139SBM0905A

9-5. Toner Bottle Vibration When the indentations at three places on the left-hand side (as viewed when the Toner Bottle is in position) of the Toner Bottle move past the protrusion in the Toner Bottle Holder, the Toner Bottle is vibrated to prevent some of the toner from remaining unconsumed in the Bottle.

Toner Bottle

Indentations

Toner Bottle Holder Protrusion

M-24

1151SBM0906A

9-6. Toner Replenishing Control 1. The ATDC Sensor installed in the Imaging Unit reads the toner-to-carrier ratio of the developer in the Developer Mixing Chamber for each copy cycle. 2. It samples the ratio 16 times and compares each with the preset level. 3. If eight or more readings out of the total 16 are lower than the preset level, a Toner Replenishing signal is output. 4. Toner Replenishing Motor M8 is turned one complete turn for each Toner Replenishing signal (which is equivalent to a supply of 0.45 g toner). *The readings taken while M8 is turning (it takes 5 seconds for M8 to turn one complete turn) are ignored. This means that, in a multi-copy cycle, the ATDC Sensor may take readings as the next copy cycle is started while M8 is turning; but, those readings are ignored.
Control Signal M8 PWB-A PJ6A-5 Control Signal PC112 PWB-A PJ22A-10 Control Signal Energized H Blocked L Set T/C 4.0% 4.5% 5.0% UN3 PWB-A PJ1A-3 5.5% 6.0% 6.5% 7.0% Deenergized L Unblocked H Reference Voltage 2.692 2.596 2.5 2.404 2.308 2.212 2.116 30-B WIRING DIAGRAM 30-E WIRING DIAGRAM 30-E WIRING DIAGRAM

M-25

1151SBM1000A

10 DRUM CHARGING
The PC Drum Charge Corona has a Scorotron grid to deposit a negative DC charge evenly across the surface of the PC Drum. The grid voltage (VG) applied to the grid mesh is selected between -650V in the normal mode and -520V in the Photo mode by the Constant-Voltage Circuit in High Voltage Unit HV1. The Corona Unit has a Comb Electrode which minimizes the amount of ozone produced. The conventional wire type corona unit produces a large amount of ozone due to corona discharge in radial directions. The comb electrode type, on the other hand, discharges only toward the Grid Mesh, meaning a reduced amount of ozone is produced. The Comb Electrode can be cleaned by the user who pulls out to the front the shaft on which a Cleaning Rollar is mounted.

Holder

Comb Electrode

Spring

Holder

Grid Mesh

Control Signal PC Drum Charge Corona PWB-A PJ12A-5

ON L Normal Mode L

OFF H

WIRING DIAGRAM 11-E

Control Signal Grid Voltage (VG) PWB-A PJ12A-6

Photo Mode H

WIRING DIAGRAM 11-E

M-26

1151SBM1100A

11 IMAGE ERASE LAMP

To prevent a black band from occurring across both the leading and trailing edges, and along the front and rear edges, of the electrostatic latent image, 31 LEDs of Image Erase Lamp LA3 are turned ON before development takes place, thereby reducing to a minimum the unnecessary potential on the surface of the PC Drum. Because of the light path involved, this copier has this edge erasing cycle between drum charging and exposure.

PC Drum Charge Corona

Image Erase Lamp LA3

Exposure

The position of LA3 can be adjusted using the adjusting screw on the front of the copier.

Copier Front Frame

Copier Rear Frame

Adjusting Screw

Compression Coil Spring

LA3 Board

LA3 Holder

M-27

The 31 LEDs of LA3 are grouped as shown below. The diagram on the bottom of this page shows which LEDs turn ON and OFF for different paper sizes and different zoom ratios.
LED Group No. 00 01 02 03 04 05 06 07 08 09 LED LED LED LED LED LED LED LED LED LED LED No. 1 2 to 6 7 to 11 12 to 16 17 18 19 20 21 22 LED Group No. 10 11 12 13 14 15 16 17 18 LED LED LED LED LED LED LED LED LED LED No. 23 24 25 26 27 28 29 30 31

*The smaller the number, the nearer the LED is to the front side of the copier.

LED ON/OFF Pattern

Zoom Ratio From - To Less Than (%) 50~53 53~57 57~61 61~64 64~67 67~70 70~74 74~78 78~82 82~86 86~90 90~93 93~96 96~99 99~ f:ON; y:OFF Paper Width From - To Less Than (mm) to 152 152 to 163 163 to 173 173 to 183 183 to 192 192 to 201 201 to 212 212 to 223 223 to 235 235 to 247 247 to 259 259 to 270 270 to 281 281 to 291 291 to LED Group No. 00 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 f y y y f f f f f f f f f f f f f f f f y y y y f f f f f f f f f f f f f f f y y y y y f f f f f f f f f f f f f f y y y y y y f f f f f f f f f f f f f y y y y y y y f f f f f f f f f f f f y y y y y y y y f f f f f f f f f f f y y y y y y y y y f f f f f f f f f f y y y y y y y y y y f f f f f f f f f y y y y y y y y y y y f f f f f f f f y y y y y y y y y y y y f f f f f f f y y y y y y y y y y y y y f f f f f f y y y y y y y y y y y y y y f f f f f y y y y y y y y y y y y y y y f f f f y y y y y y y y y y y y y y y y f f f y y y y y y y y y y y y y y y y y f

*Max. width (291 mm or more) applies to manual bypass copying in which the copier is unable to detect paper width.

M-28

Control Signal LA3 PWB-A PJ17A-4 ~ 9

ON L

OFF H

WIRING DIAGRAM 2-F

M-29

1151SBM1200A

12 OPTICAL SECTION
As the Scanner is moved by Scanner Motor M5, the light from Exposure Lamp LA1 is reflected off the original and guided through the four Mirrors onto the surface of the PC Drum to form the electrostatic latent image. The image is enlarged or reduced as necessary by changing the position of the Lens and 4th Mirror and varying the angle of the 4th Mirror.

4th Mirror

Mirror Motor M7

Scanner Lens Motor M6 AE Sensor

2nd/3rd Mirrors Carriage

Lens Scanner Motor M5 Scanner Shaft

M-30

1151SBM1201A

12-1. Exposure Lamp LA1 An AC halogen lamp is used as Exposure Lamp LA1. As the exposure level is adjusted on the control panel, the duty ratio of the pulse of AVR Remote from PWB-A changes to increase or decrease the LA1 voltage, thereby changing the image density. In Photo mode, the voltages are varied on a level 5V lower than the manual Exposure Lamp voltages.
Manual EXP Setting Lamp Voltage Difference (V) 9 8 8 4 7 2 6 1 5 Reference 4 +1 3 +2 2 +4 1 +8

Control Signal AVR Remote Signal (LA1) PWB-A PJ12A-11

ON L

OFF H

WIRING DIAGRAM 22-F, 22-H

*If reduction copies are made using large size paper, the trailing edge of the first copy moves past PC51 after the SCEND signal for the second copy has been generated. If LA1 is turned ON for the second copy at the same timing as the first one, therefore, the image for the second copy is produced on the trailing edge of the first copy. To prevent this from occurring, LA1 is turned ON for the second and subsequent copies when all of the following conditions are met: D Approx. 0.8 sec. or more have elapsed after the first copy deactivated PC51. D The PC51 output is HIGH. D The SCEND signal for the second copy is output.

M-31

1151SBM1202A

12-2. AE Sensor In the Auto Exposure Mode, the AE Sensor on AE Sensor Board PWB-H measures the intensity of the light reflected off the original, which results in the black/white ratio of a 210-mm-wide area from the reference position of the original being measured. According to this measurement, the Exposure Lamp voltage is automatically increased or decreased so that copies of consistent quality are produced. The output from the AE Sensor is applied to PWB-A which, in turn, varies the duty ratio of the AVR Remote from it to vary accordingly the LA1 voltage.
Original Density (B/W Ratio) Intensity of Reflected Light PWB-H Output AVR Duty LA1 Voltage Control Signal PWB-H (AE Sensor) AVR Remote Signal (LA1) PWB-A PJ2A-3 High Low High Increased Increased ON L Low High Low Decreased Decreased OFF H WIRING DIAGRAM 21-L

PWB-A PJ12A-11

22-F, 22-H

M-32

1151SBM1203A

12-3. Lamp Reflectors The Main Reflector ensures that light from Exposure Lamp LA1 exposes all areas of the original. The Auxiliary Reflector functions to reflect light onto the areas that LA1 cannot illuminate when an original that does not lie flat on the Original Glass (such as a book) is being used. This reduces shadows which would otherwise be transferred to the copy. The Main Reflector is of aluminum, while the Auxiliary Reflector is aluminum to which film has been deposited. The same film as that used on the Auxiliary Reflector is affixed to both ends of the frame to compensate for the reduced intensity of light around both ends of the Exposure Lamp.

Auxiliary Reflector

Main Reflector

Exposure Lamp LA1

1151M021AA

1151SBM1204A

12-4. Aperture Plates Four Aperture Plates are moved to the front and rear to ensure even light distribution.

Aperture Plate

1151M020AA

M-33

1151SBM1205A

12-5. Scanner and 2nd/3rd Mirror Carriage Movement The Scanner and 2nd/3rd Mirrors Carriage are moved by the Scanner Drive Cable fitted in the rear side of the copier. The Cable is driven by Scanner Motor M5. Both the Scanner and 2nd/3rd Mirrors Carriage slide along the Scanner Shaft at the rear side. While at the front side, there is a Slide Bushing attached to the underside of each of the bodies and that Bushing slides over the Slide Rail. The speed of the Scanner and 2nd/3rd Mirrors Carriage varies with different zoom ratios. Scanner Reference Position Sensor PC81 detects the home position of the Scanner and 2nd/3rd Mirrors Carriage. If they are not at the home position when the copier is turned ON, M5 is energized to move them to the home position.

2nd/3rd Mirrors Carriage Scanner

Slide Rail

Scanner Shaft

Scanner Reference Position Sensor PC81 Scanner Motor M5 Scanner Drive Cable
1151M022YA

M-34

The Scanner starts the scan motion as a Scan Sel signal (PJ16A-3) is output from PWB-A. At the start of a scan motion and other heavy load conditions, Scanner Motor M5 requires a large amount of current. The Current 1 or 2 signal (PJ16A-10 or 11) from PWB-A is selected accordingly to vary the amount of current supplied to M5. *The Current signal selection timing is controlled by software.
Current 1 Current 2 Current H H Approx. 0.6A When the scan speed reaches a given level and during return braking. L H Approx. 0.7A At scan start and when the return speed reaches a given level. L L Approx. 0.9A At return start and at scan start for low zoom ratio

On receiving the Scan Sel signal, Motor Drive Board PWB-E applies motor drive pulses, which are out-of-phase with each other, to M5. The motor speed is varied by changing the width of the pulses applied to M5.
Control Signal M5 Sel Signal M5 Current Switching Signal 1 M5 Current Switching Signal 2 Control Signal PC81 PWB-A PJ22A-1 Blocked L Unblocked H WIRING DIAGRAM 20-N PWB-A PJ16A-11 L H PWB-A PJ16A-10 L H 22-J PWB-A PJ16A-3 Energized L Deenergized H WIRING DIAGRAM

M-35

1151SBM1206A

12-6. 4th Mirror Movement The 4th Mirror is moved to vary the conjugate distance for a particular zoom ratio by driving the rack-and-pinion gears at the front and rear ends of the mirror using Mirror Motor M7 (stepping motor). The Levers of the Holder to which the Mirror is mounted slides along a tilted rail to change the Mirror angle. This ensures that the light strikes the surface of the PC Drum in the direction of the normal, thereby preventing resolution from being degraded. Mirror Reference Position Sensor PC81 is used to control the position of the 4th Mirror. It ensures that the Mirror is located at the home position when the copier is turned ON.

Levers

Drive Shaft 4th Mirror Mirror Motor M7 Tilt Adjusting Screw

Lever

Control Signal M7 PWB-A PJ16A-2 Control Signal PC86 PWB-A PJ20A-2

Energized L Blocked L

Deenergized H Unblocked H

WIRING DIAGRAM 19-I WIRING DIAGRAM 20-M

M-36

1151SBM1207B

12-7. Lens Movement The Lens is moved by the Lens Drive Cable which is driven by Lens Motor M6 (stepping motor). The motor drive pulses sent from PWB-E drive M6 to move the Lens a given distance, corresponding to the zoom ratio, from the reference position determined by Lens Reference Position Sensor PC90. There is a fixed-type Lens Aperture Cover provided at the rear of the Lens (on the 4th Mirror end). It limits the amount of light striking the surface of the PC Drum.
Lens Reference Position Sensor PC90 Lens Base Bracket Lens Lens Aperture Cover

Shaft

Spring Lens Drive Cable

Cam

Lens Motor M6
1151M023AA

Lens

1149M010AA

Lens Aperture Cover

Control Signal M6 PWB-A PJ16A-1 Control Signal PC90 PWB-A PJ20A-5

Energized L Blocked L

Deenergized H Unblocked H

WIRING DIAGRAM 19-I WIRING DIAGRAM 20-M

M-37

1151SBM1400A

14 MAIN ERASE LAMP

Main Erase Lamp LA2 is turned ON to neutralize any surface potential remaining on the surface of the PC Drum after cleaning.
Mounting Bracket Main Erase Lamp LA2

PC Drum Slit

LA2 consists of ten tungsten-filament lamps mounted on a Board.

Slit

Tungsten-Filament Lamp Mounting Bracket

Copier Front Frame

Control Signal LA2 PWB-A PJ1A-7

ON H

OFF L

WIRING DIAGRAM 31-C

M-38

1151SBM1500A

15 IMAGE TRANSFER AND PAPER SEPARATION

Image Transfer The Image Transfer Corona applies a DC negative corona emission to the underside of the paper thereby attracting the positively charged toner onto the surface of the paper to form a visible, developed image of the original. The Corona Unit is provided with a Corona Wire cleaning mechanism: the operator has only to pull out the Lever on which the Cleaner is mounted from the front of the copier, which cleans the Wire. Paper Separation The Paper Separator Corona showers the underside of the paper with both positive and negative charges so that the paper can be easily separated from the PC Drum. In addition, two Paper Separator Fingers physically peel the paper off the surface of the PC Drum. (For details, see PAPER SEPARATOR FINGERS.) The Image Transfer/Paper Separator Coronas Unit is provided with a Pre-Image Transfer Guide Plate that determines the angle at which the paper comes into contact with the PC Drum and keeps an optimum distance between the paper and the PC Drum so that the image may be properly transferred onto the paper.

PC Drum

Housing Pre-Image Transfer Guide Plate Paper Separator Corona Wire Image Transfer Corona Wire

Cleaner Lever

Cleaner

M-39

Control Signal Image Transfer Corona Paper Separator Corona PWB-A PJ12A-5

ON L

OFF H

WIRING DIAGRAM 11-E

PWB-A PJ12A-4

11-E

M-40

1151SBM1600A

16 PAPER SEPARATOR FINGERS

After image transfer, an AC corona emission is applied to the underside of the paper by the Paper Separator Corona to neutralize the paper so that it can be easily separated from the PC Drum. To further ensure that the paper is positively separated from the PC Drum, there are two Paper Separator Fingers attached to the Imaging Unit. They physically peel the paper off the surface of the PC Drum. To prevent the Paper Separator Fingers from damaging the surface of the PC Drum, they are kept in the retracted position whenever they are not at work. As illustrated below, the Fingers are brought into contact with, and retracted from, the surface of the PC Drum by the Lever which is operated by Separator Solenoid SL1.
Where Fingers are in Contact with PC Drum Lever Pressure Spring Where Fingers are Retracted from PC Drum

Holder Separator Finger

The Paper Separator Fingers are also moved over a given distance to the front and rear so that they will contact wider areas of the surface of the PC Drum, thus preventing localized damage to the PC Drum surface. This lateral movement is done by the Lever connected to the Cleaning Blade and, when the Cleaning Blade is moved, the Separator Fingers are also moved back and forth. *Lateral Movement: 3.7 mm

Cleaning Blade

Lever Holder

100 mm

80 mm Paper Path Reference Position

Finger Positions

M-41

Control Signal SL1 PWB-A PJ14A-2

Energized L

Deenergized H

WIRING DIAGRAM 14-A

M-42

1158SBM1700A

17 PAPER TAKE-UP/FEED SECTION

The copier is equipped with one universal paper size Drawer that can hold up to 250 sheets of paper.
Paper Take-up Solenoid Drawer Set Detecting Switch S65 Marketing Area Switch Paper Size Detecting Switches Paper Take-Up Rolls Paper Take-Up Sensor Paper Empty Sensor

Paper Drawer (Universal Paper Size)

Paper Sizes That Can be Loaded

Marketing Area Switch S66 Inch Inch Areas Metric Metric Inch
]

Paper Drawer 5.58.5, 8.511, 8.514, 118.5, 1114, 1117 A5L, A4L, A4C, A3L, 813, 8.513 [G.LEGAL], 8-1/413 A3L, B4L, A4L, A4C, A5L, B5C, B5L (Taiwan Only), 813], 8.513, 8-1/413 5.58.5 [INVOICE], 8.511 [LETTER]], 8.514 [LEGAL]], 1117]

Metric Areas

Except Taiwan

M-43

1158SBM1701A

17-1. Edge Guide and Trailing Edge Stop Paper Drawer The Paper Drawer is a universal type allowing the user to slide freely the Edge Guide and Trailing Edge Stop to accommodate paper of different sizes. The Edge Guide and Trailing Edge Stop can be locked into position by meshing the notches in the Lock Lever with those in the Drawer.

Drawer Side Lock Lever

Trailing Edge Stop

Edge Guide

M-44

1158SBM1702A

17-2. Drawer Positioning The Paper Drawer is positioned by fitting its Positioning Plate on the paper take-up end into the groove in the Drawer Frame. It is then secured in position by the magnet installed in the Drawer Front Cover on the paper take-up end. The tabs on both sides at the front of the Drawer ensure that the Drawer clicks into position. Any deviation in the paper path reference position can be adjusted within "2 mm by moving the Front Cover of the Drawer to the front or rear.
Tab Rear End

Positioning Plate

Front End Position Plate

1151M024AA

1158SBM1703A

17-3. Paper Lifting Plate The Paper Lifting Plate of the Drawer is raised at all times by two Paper Lifting Springs.

Paper Lifting Plate

Paper Lifting Springs

M-45

1158SBM1704A

17-4. Drawer-in-Position Detection The copier detects that the Drawer is slid into position as follows. When the Drawer is slid into the copier, the Drawer Frame presses Drawer Set Detecting Switch S65 installed on the back panel of the copier.
Paper Size Detecting Switches Drawer Set Detecting Switches S65

S61 S62S63

Drawer Frame

<Control>
Control Signal S65 PWB-A PJ9A-13 ON L OFF H WIRING DIAGRAM 25-G

M-46

1158SBM1705A

17-5. Universal Tray Paper Size Detection The length (feeding direction) and width (crosswise direction) of the paper are independently detected and the copier determines the paper size by combining the two separate detections made. On the bottom of the tray are a lever fitted to the Trailing Edge Stop and another lever fitted to the Edge Guide. These levers actuate and deactuate Paper Size Detecting Switches S61, S62, S63, and S64 to allow the copier to determine a particular paper size.
Marketing Area Switch S66 is used to set the type of paper to be used (inch or metric).
S62 S61 S63

S66

S64

Drawer Set Detecting Switch S65

NOTE The number and the installed position of the Paper Take-Up Rolls vary depending on the marketing areas: inch or metric. See pp. M-43 for the sizes of the paper that can be taken up and fed out of the drawer.
1151M003AA

Paper Size Detecting Switches Length (FD) S61 ON ON ON OFF OFF OFF OFF S62 ON ON OFF OFF OFF ON ON S63 ON OFF OFF OFF ON ON OFF Width (CD) S64 OFF ON OFF ON OFF ON OFF ON OFF ON ~402.0 402.0~349.2 349.4~317.2 317.2~272.0 272.0~222.0 222.0~195.0 195.0~ Paper Length

Inch/Metric Setting Switch S66 Metric A3 B4 FLS A4L B5L A5L A4L B5C Inch 11  17 8-1/2  14 11  14 8-1/2  14 11  14 Letter L Letter L Letter C Invoice L Letter C Letter C Letter L

M-47

<Control>
Control Signal S61 S62 S63 S64 S66
1158SBM1706A

ON L L L L L

OFF H H H H H

WIRING DIAGRAM 25-D 25-E 25-E 25-F 25-G

PWB-A PJ9A-1 PWB-A PJ9A-4 PWB-A PJ9A-7 PWB-A PJ9A-10 PWB-A PJ10A-4

17-6. Paper Empty Detection When the Drawer runs out of paper, the Actuator for the Paper Empty Sensor drops into the cutout in the Paper Lifting Plate. This activates the Paper Empty Sensor and the copier will know that the Drawer has run out of paper. As we noted earlier, the Paper Lifting Plate is raised at all times by the Paper Lifting Springs. To prevent the Actuator for the Paper Empty Sensor (PC101) from being caught by the paper stack when the Drawer is slid out of the copier, therefore, it is tilted slightly. This, however, results in the operating stroke of the Actuator becoming small, which increases the possibility of the Actuator activating the Sensor by flexing of a sheet of paper as it is taken up and fed in. To prevent this false detection a paper-empty condition, the paper empty detection is enabled only when the Paper Take-Up Roll is in the retracted position. (See 16-8. Paper Take-Up Roll for the retracted position of the Paper Take-Up Roll.)
Paper Empty Sensor

Actuator

<Control>
Control Signal PC101 PWB-A PJ7A-6 Blocked L Unblocked H WIRING DIAGRAM 25-B

M-48

1158SBM1707A

17-7. Paper Separating Mechanism The Drawer has Fingers that function to separate the top sheet of paper from the rest of the paper stack at paper take-up. The Fingers are fitted to the right front and rear corners of the Drawer. When the Paper Take-Up Roll starts turning to take up the top sheet of paper, its turning force is directly transmitted to the top sheet of paper as it is in direct contact with the Paper Take-Up Roll. That force overcomes the block of the Fingers, causing the top sheet of paper to ride over the Fingers and be fed out of the Drawer into the copier. As to the second sheet of paper, the paper transport force obtained through friction with the top sheet of paper is weak and does not allow the second sheet of paper to ride over the block of the Fingers. Hence, the second sheet of paper remains stationary with the rest of the paper stack in the Drawer. When there are only two sheets of paper left in the Drawer, the bottom sheet can be fed with the top one if the friction of the Paper Lifting Plate is weak. The Friction Plate affixed to the Paper Lifting Plate prevents this from happening.

Paper Take-Up Roll

Paper

Separator Finger

Friction Plate

Paper Lifting Plate

M-49

1158SBM1708A

17-8. Paper Take-Up Roll Since the Paper Lifting Plate is raised at all times by the Paper Lifting Springs, paper is wedged in the mechanism when the Drawer is slid out of the copier if the Paper Take-Up Roll is round in shape. So the Take-Up Roll is semicircular and the circular part of the Roll is positioned on top at times other than take-up. For convenience, we call this position of the Paper Take-Up Roll the retracted position. The Paper Take-Up Roll is grooved to keep good friction even under heavy loading. The Paper Drawer, which is a universal type to accommodate paper of different sizes, is provided with five (four in areas using only inch paper) Paper Take-Up Rolls. The Paper Take-Up Roll is driven when the Paper Take-Up Solenoid (SL2) is energized. The Roll is turned one complete turn for each single sheet of paper. The Paper Take-Up Sensor (PC55) is used to detect whether a sheet of paper has been properly taken up or not.
Paper Take-Up Solenoid Paper Take-Up Roll Ratchet

Ratchet
1151M025AA

Vertical Transport Roller Paper Take-Up Sensor

Actuator

M-50

Control Signal SL2 PWB-A PJ7A-9 Control Signal PC55

1158SBM1709A

Energized L Blocked H

Deenergized H Unblocked L

WIRING DIAGRAM 25-C WIRING DIAGRAM 25-B

PWB-A PJ7A-2

17-9. Paper Take-Up Retry Control To minimize the occurrence of paper misfeed due to a slippery Paper Take-Up Roll, the Paper Take-Up Solenoid is energized a second time if a sheet of paper fails to reach the Paper Take-Up Detecting Sensor within 1.3 sec. after the solenoid has been deenergized. The solenoid is energized a second time 0.5 sec. after the above-mentioned period of 1.3 sec. has elapsed. (This is referred to as the paper take-up retry function.) A misfeed results if the sheet of paper does not reach the Paper Take-Up Detecting Sensor even after the three paper take-up sequences. Here is the control timing chart.

M-51

1151SBM1800A

18 VERTICAL PAPER TRANSPORT

The sheet of paper taken up by the Paper Take-Up Roll from the Drawer is fed along the Paper Guide to the Vertical Transport Rollers. The paper fed by the Vertical Transport Rollers reaches the Transport Rollers and is then fed up to the Synchronizing Rollers. The Transport Rollers are turned and stopped by Paper Transport Clutch CL2. Transport Roller Sensor PC51 immediately before the Transport Rollers detects a sheet of paper fed from the Vertical Transport Section or Manual Bypass Table. The Cover for the Vertical Transport Section (i.e., the Side Door) can be opened and closed for clearing misfeeds. Side Door Detecting Sensor PC57 detects whether or not this Cover is open.

Transport Rollers Actuator Transport Roller Sensor PC51 Side Door Detecting Sensor PC57 Vertical Transport Rollers/Rolls.
1142M006AA

<Control>

Control Signal M2 CL2 PWB-A PJ12A-10 PWB-A PJ6A-2 Control Signal PC54 PWB-A PJ18A-2

Energized L L Blocked L

Deenergized H H Unblocked H

WIRING DIAGRAM 5-F 2-M WIRING DIAGRAM 14-D

M-52

1151SBM1900B

19 SYNCHRONIZING ROLLERS
The Synchronizing Rollers, operating in phase with the Scanners scan motion and paper feeding, synchronize the leading edge of the copy paper accurately with the leading edge of the toner image on the PC Drum. The Upper Synchronizing Roller is a metal roller covered with a polyvinyl chloride tubing, while the Lower one is a rubber roller.
Upper Synchronizing Roller Synchronizing Roller Clutch CL1

Lower Synchronizing Roller Paper Leading Edge Detecting Sensor PC54

1151M026AA

To facilitate clearing of misfeeds, the Upper Synchronizing Roller is installed in the Imaging Unit. It is fitted to the Guide Frame of the Imaging Unit and the Compression Springs at the front and rear ends press the Roller downward so that it makes contact with the Lower Synchronizing Roller. The Lower Roller is driven by the drive source, while there is a gear train that transmits the rotation of the Lower Roller to the Upper Roller, thus ensuring good paper transport performance. To ensure good image transfer during conditions of high humidity, the Pre-Synch Guide Plate is electrically floated by a plastic spacer, grounded through an 82M resistor and 1kV varistor.
Upper Synchronizing Roller Compression Spring

Pre-Image Transfer Guide Plate

Guide Frame Pre-Synch Guide Plate Paper Leading Edge Detecting Sensor PC54

Lower Synchronizing Roller Actuator

M-53

1151SBM1901A

19-1. Upper Synchronizing Roller Positioning Since the Upper Synchronizing Roller is fitted to the Imaging Unit, it must be correctly positioned with reference to the Lower Synchronizing Roller when the Upper Half of the copier is swung down into the locked position. For this purpose, slits are cut in the lower copier frame and the Bushings of the Upper Synchronizing Roller fit into these slits. The Upper Synchronizing Roller is grounded through the Bushings which are in contact with the frame. To positively ground the Roller, the Ground Plate fitted to the lower frame makes contact with the Shaft of the Upper Synchronizing Roller.
Upper Synchronizing shaft Lower Copier Frame

Ground Plate
1151M027YA

1151SBM1902A

19-2. Paper Dust Remover The Paper Dust Remover is installed so that it makes contact with the Upper Synchronizing Roller. Since the Upper Synchronizing Roller is covered with a vinyl tubing, triboelectric charging occurs as the Roller turns in contact with the Paper Dust Remover. As paper is then fed between the Synchronizing Rollers, the charges on the tubing attract paper dust from the paper. The dust is then transferred onto the Paper Dust Remover.

Upper Synchronizing Roller

Paper Dust Remover

Lower Synchronizing Roller

M-54

1151SBM1903A

19-3. Synchronizing Roller Control The Synchronizing Rollers are started as Synchronizing Roller Clutch CL1 is energized upon reception of a signal from PWB-A.

Control Signal CL1 PWB-A PJ6A-4 Control Signal PC54 PWB-A PJ18A-2

Energized L Blocked L

Deenergized H Unblocked H

WIRING DIAGRAM 2-N WIRING DIAGRAM 14-D

M-55

1151SBM2000A

20 PAPER TRANSPORT
After having gone through the image transfer and paper separation processes, the paper is then transported to the Fusing Unit by the Suction Belts of the Suction Deck driven directly by Main Drive Motor M2. Suction Fan Motor M4 draws the paper onto the turning Suction Belts for positive transport of the paper.
Suction Fan Motor M4

Suction Belts

1151M005AA

Control Signal M2 M4 PWB-A PJ12A-10 PWB-A PJ6A-8

Energized L L

Deenergized H H

WIRING DIAGRAM 5-F 2-O

M-56

1151SBM2100A

21 FUSING UNIT
The Upper Fusing Roller and Lower Fusing Roller together apply heat and pressure to the toner and paper to permanently fix the developed image to the paper. Drive for the Upper Fusing Roller is transmitted from the Main Drive Motor to the Upper Fusing Roller Drive Gear. The Lower Fusing Roller, Cleaning Roller and Oil Roller are driven by the respective Rollers in contact with them.

Fusing Thermistor TH1 Fusing Thermoswitch Fusing Heater Lamp H1 Paper Exit Roll

Upper Fusing Roller Lower Fusing Roller

Oil Roller

Pressure Spring

Cleaning Roller

1151M011AA

Paper Exit Roller Drive Gear

Upper Fusing Roller Drive Gear

1151M007AA

M-57

1151SBM2101A

21-1. Fusing Temperature Control The Upper Fusing Roller is heated by Fusing Heater Lamp H1 which is an AC halogen lamp. Fusing Thermistor TH1 installed on the Upper Fusing Roller helps keep the optimum fusing temperature. The fusing temperature is normally controlled at 195C. To ensure good fusing performance, however, even when the Lower Fusing Roller remains cool immediately after warm-up in the early morning, the temperature is controlled as follows when the copier is turned ON: *If the initial fusing temperature is less than 90C: Temperature is controlled at 205C for 10 min. after the copier has completed warming up, which is followed by a temperature control at 195C. *If the initial fusing temperature is less than 150C: Temperature is controlled at 205C for 1 min. after the copier has completed warming up, which is followed by a temperature control at 195C. *If the initial fusing temperature is more than 150C: Temperature is controlled at 195C after the copier has completed warming up. TH1 is positioned at a point 84 mm from the paper path reference position, thereby preventing offset caused by low temperature and degraded fusing performance for small-size paper. The control temperature in the Energy Saving Mode is 100C. Fusing Thermoswitch TS1, installed above the Upper Fusing Roller, cuts off the power to the Fusing Unit if the temperature of the Upper Fusing Roller becomes excessively high. It eliminates the possibility of a fire that could occur when H1 remains ON due to a faulty temperature control circuit.

M-58

1151SBM2102A

21-2. Fusing Rollers Pressure Mechanism Pressure Springs are installed at both ends of the Lower Fusing Roller. These springs contact the bearings mounted on both ends of the Lower Fusing Roller and exert pressure through the Lower Fusing Roller to the Upper Fusing Roller which is installed in the Fusing Unit. The Fusing Unit is divided into an upper and a lower half, and the upper half can be swung open. The Upper Half of the copier, when locked in position, presses the upper half of the Fusing Unit down onto its lower half.
Upper Copier Frame

Upper Fusing Roller

Pressure Spring

Lower Fusing Roller

1151SBM2103A

21-3. Oil Roller/Cleaning Roller A felt-type silicone Oil Roller is pressed up against the Lower Fusing Roller by the Torsion Springs fitted on the bushings on both ends of the Oil Roller. The Oil Roller applies a coat of silicone oil to the surface of the Lower Fusing Roller. From there, it is transferred to the surface of the Upper Fusing Roller to help prevent toner from being melted onto the surface of the Upper Fusing Roller. The Cleaning Roller is pressed against the surface of the Lower Fusing Roller, thus assisting cleaning of the fusing rollers.

Upper Fusing Roller

Lower Fusing Roller Cleaning Roller Oil Roller

1151M008AA

M-59

1151SBM2200A

22 EXIT UNIT
The Paper Exit Roller/Rolls feed the paper, to which the developed image has been fixed, out of the Fusing Unit onto the Copy Tray. The Charge Neutralizing Brush touches the surface of the sheet of paper being fed out of the Fusing Unit to neutralize any static charge left on it. The Upper and Lower Separator Fingers strip the paper from the surface of the Upper/Lower Fusing Roller.
Paper Exit Roll Charge Neutralizing Brush Upper Separator Finger

Paper Exit Roller

Lower Separator Finger

1151SBM2201A

22-1. Upper/Lower Separator Fingers The Upper and Lower Separator Fingers are laid out as shown below to cope with many different paper sizes.
A3 B4 A4 B5 A5 B6 A6

273

231 250.6

158 175.6

106 122.6

Upper Separator Fingers

Paper Path Reference Position *Unit: mm Lower Separator Fingers 36.6

19

M-60

1151SBM2202B

22-2. Paper Exit Sensor 1st Paper Exit Sensor PC53 installed in the paper exit section of the lower half of the copier detects the sheet of paper being fed out of the Fusing Unit onto the Copy Tray.

Actuator

Paper Exit Roller

1 st Paper Exit Sensor PC53

Control Signal PC53 PWB-A PJ21A-2

Blocked L

Unblocked H

WIRING DIAGRAM 14-F

M-61

1158SBM2400A

24 DEHUMIDIFYING SWITCH (OPTION)

To prevent image transfer efficiency from being reduced due to damp paper in highly humid weather, Paper Dehumidifying Heater H3 is installed on the base frame of the copier under the Drawer. While, Drum Dehumidifying Heater H2 is located under the Lower Synchronizing Roller to prevent the PC Drum from forming condensation.
Lower Synchronizing Roller

Paper Take-Up Rolls

Drum Dehumidifying Heater H2

Serviceman Switch S3

Base frame Paper Dehumidifying Heater H3

D H2, H3 ON/OFF Conditions

Serviceman Switch ON Power cord Plugged in H2 H3 ON ON Power Switch ON OFF ON *During a copy cycle OFF OFF

*During a copy cycle: Refers to the period of time between when the Start Key is pressed and when Main Drive Motor M2 is deenergized.

M-62

1158SBM2500A

25 MULTI BYPASS TABLE MB-4 (Option)

The optional Multi Bypass Table permits the user to make multiple copies (up to 50) on paper that cannot be fed automatically via any built-in paper drawer of the copier.

Lever

Paper Empty Sensor (MB-4) PC32 Paper Take-Up Clutch (MB-4) CL51 Paper Take-Up Solenoid (MB-4) SL51 Paper Take-Up Roll

M-63

1151SBM2501A

25-1. Paper Take-Up Mechanism The Paper Take-Up Rolls are normally in their raised (retracted) position so that they will not hamper proper loading of paper. When the Start Key is pressed, Paper Take-Up Solenoid (MB-4) SL51 is deenergized causing the Paper Take-Up Rolls to press the paper stack downward and take up a sheet of paper. There are Paper Stoppers provided that block the leading edge of the paper stack as it is loaded on the Table, preventing any portion of the leading edge of the paper from getting inside. These Stoppers are unlocked at paper take-up, allowing paper into the copier. Paper Take-Up Clutch (MB-4) CL51 controls the turning and stop of the Paper TakeUp Rolls.
In Standby

Lock Levers

Lever Rack Gear

Paper Take-Up Rolls Paper Take-Up Solenoid (MB-4) SL51 Paper Stoppers At Take-Up

M-64

Control Signal CL51 SL51 Down SL51 UP PWB-A PJ11A-4 PWB-A PJ11A-2 PWB-A PJ11A-3

Energized L L L

Deenergized H H

WIRING DIAGRAM 30-G

30-G H

M-65

1151SBM2502A

25-2. Paper Separating Mechanism The paper separating mechanism ensures that only the top sheet of paper is fed in by separating the second sheet of paper from the top one. This is accomplished by the Torque Limiter fitted to the Separator Roll shaft which stops the Separator Roll when there is a change in friction between the Feed and Separator Rolls. 1. At the Time of Double Feed: The top sheet of paper is fed into the copier by the Feed Roll. Since the coefficient of friction between the top and second sheet of paper is smaller than that between the second sheet of paper and the Separator Roll, the two sheets of paper slip and the second sheet of paper is not fed into the copier. The driving force of the Feed Roll is at this time consumed by the two slipping sheets of paper and not transmitted to the Separator Roll which is stopped by its Torque Limiter. In other words, the force of the Torque Limiter is greater than the driving force of the Feed Roll as it is transmitted through the two sheets of paper.

Feed Roll

Separator Roll *Stationary in this condition.

2. Normal Feeding: The friction coefficient on the top side of the paper is equivalent to that on the underside. Hence, the driving force of the Feed Roll is directly transmitted to the Separator Roll through the paper, causing the Separator Roll to be turned by the Feed Roll. In other words, the force of the Torque Limiter is smaller than the driving force of the Feed Roll as it is transmitted through the paper.

M-66

1151SBM2503A

25-3. Paper Empty Detection The Multi Bypass Table is equipped with Paper Empty Sensor (MB-4) PC31 which detects a sheet of paper at the manual bypass port.
Paper Empty Sensor (MB-4) PC31

Paper Take-Up Roll Paper Stopper Actuator

Control Signal PC31 PWB-A PJ11A-6

Blocked L

Unblocked H

WIRING DIAGRAM 30-H

M-67

1151SBM2700A

27 COOLING FAN
Ozone produced by the PC Drum Charge Corona and Image Transfer/Paper Separator Coronas is drawn out of the copier by Cooling Fan Motor M9 and absorbed by the Ozone Filter. M9 is turned either at high or low speed. It turns at high speed for 3 seconds during a copy cycle and after the Power Switch is turned ON.
Cooling Fan

PC Drum Charge Corona Duct Image Transfer/Paper Separator Coronas

1151M009AA

Control Signal M9 PWB-A PJ6A-9

Energized H

Deenergized L

WIRING DIAGRAM 2-O

M-68

1151SBM2800A

28 OPTICAL SECTION COOLING FAN

Optical Section Cooling Fan Motor M3 draws outside air into the copier and blows it against the Original Glass which is heated by lit Exposure Lamp LA1. The Filter at the intake port of the Fan prevents dust and dirt from entering the Optical Section of the copier. M3 turns only during a copy cycle.
Front of Copier Original Glass Filter

Outside Air

Optical Section Cooling Fan Motor M3

Control Signal M3 PWB-A PJ32A-2

Energized L

Deenergized H

WIRING DIAGRAM 20-O

M-69

1151SBM2900A

29 MEMORY BACKUP
IC1 (RAM) of RAM Board PWB-R connected to Main Control Board PWB-A stores the setting/adjustment values set in the Tech. Rep. Modes as well as the counter counts. Backup Battery BAT1 is mounted on PWB-R to prevent the contents of memory from being lost when the power cord is unplugged or PWB-R removed from the copier. BAT1 requires a voltage of 2V or more to retain the contents of memory. Important As we noted above, the RAM stores critical data. If PWB-R has been replaced with a new one, memory must first be cleared and then all settings be made again. It should also be noted that PWB-R should not be replaced at the same time when PWB-A is replaced.

M-70

SWITCHES ON PWBs/TECH. REP. SETTINGS

1158SBS000BA

CONTENTS
1 PRECAUTIONS FOR HANDLING THE PWBs . . . . . . . . . . . . . . . . . . . S-1 1-1. Precautions for Transportation and Storage . . . . . . . . . . . . . . . . S-1 1-2. Precautions for Replacement and Inspection . . . . . . . . . . . . . . . S-1 . . . . . . . . . . . . . . . . . . . S-2

2 3

CONTROL PANEL KEYS AND INDICATORS

FUNCTIONS OF SWITCHES AND OTHER PARTS ON PWBs

. . . S-4 3-1. PWB Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-4 3-2. Tech. Rep. Setting Switches Board . . . . . . . . . . . . . . . . . . . . . . . . S-4 ................................................ 4-1. Functions Available from the User Mode . . . . . . . . . . . . . . . . . . . 4-2. User Mode Setting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3. User Mode Setting Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S-6 S-6 S-6 S-7 S-9 S-9 S-10 S-11 S-11 S-13 S-17 S-17 S-18 S-19 S-20 S-21 S-22 S-22 S-22 S-23

4 USER MODE

5 SERVICE MODE

............................................. 5-1. Service Mode Function Tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2. Entering the Service Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3. Settings in the Service Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. Tech. Rep. Choice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3. PM Counter and Ports/Options Counter . . . . . . . . . . . . . . . . . . 4. Paper Size Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. Misfeed Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6. Malfunction Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7. Parts/Supplies Life Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8. Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUST MODE

............................................. 6-1. Functions Available in the Adjust Mode . . . . . . . . . . . . . . . . . . . . 6-2. Entering the Adjust Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3. Settings in the Adjust Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FUNCTION SETTING REQUIREMENTS AT REPLACEMENT OF PARTS

. . S-25 Table of Function Setting Requirements at Replacement of Parts . . S-25

1151SBS0100A

1 PRECAUTIONS FOR HANDLING THE PWBs

1151SBS0101A

1-1. Precautions for Transportation and Storage

a) Before transporting or storing the PWBs, put them in protective conductive cases or bags so that they are not subjected to high temperature (and they are not exposed to direct sunlight). b) Protect the PWBs from any external force so that they are not bent or damaged. c) Once the PWB has been removed from its conductive case or bag, never place it directly on an object that is easily charged with static electricity (such as a carpet or plastic bag). d) Do not touch the parts and printed patterns on the PWBs with bare hands.
1151SBS0102A

1-2. Precautions for Replacement and Inspection

a) Whenever replacing the PWB, make sure that the power cord of the copier has been unplugged. b) When the power is on, the connectors should never be plugged in or unplugged. c) Use care not to strap the pins of an IC with a metal tool. d) When touching the PWB, wear a wrist strap and connect its cord to a securely grounded place whenever possible. If you cannot wear a wrist strap, touch the metal part to discharge static electricity before touching the PWB.

S-1

1158SBS0200A

2 CONTROL PANEL KEYS AND INDICATORS

* For more details, see the Operators Manual shipped with the copier. 10-Keys D Numeric keypad used for setting the number of copies to be made, and Tech. Rep. mode settings. Clear Key D Clear the number-of-copies setting, choice modes setting. Energy Saver Key D Sets the copier into the Energy Saver mode. Panel Reset Key D Resets the copier to the initial mode. Stop Key D Stops a multi-copy cycle or a test (F*) operation. Start Key D Starts a multi-copy cycle or a test (F*) operation. Zoom Ratio Select Key D Selects a fixed zoom ratio. Zoom Up/Down Keys D Changes the zoom ratio manually. Auto Exposure Mode Key D Selects either the Auto or Manual Exposure, or Photo mode. Exposure Control Keys D Selects the exposure level. Paper Select Key D Selects the paper source. Book Key D Selects the Book mode. Drum Dehumidify Key D Runs a Drum Dehumidify cycle. Auxiliary Toner Replenishing Key D Starts an auxiliary toner replenishing sequence. Meter Count Key D Gives a display of the current copy count.

S-2

1158O001DA

S-3

1151SBS0300A

3 FUNCTIONS OF SWITCHES AND OTHER PARTS ON PWBs

1151SBS0301A

3-1. PWB Location

Tech. Rep. Setting Switches Board PWB-A Board

1151SBS0302A

3-2. Tech. Rep. Setting Switches Board

1151S002AA

Symbol S1

Name Trouble Reset Switch Initialize Points

Description Resets all malfunctions including Exposure Lamp (C04XX) and fusing (C05XX) malfunctions. Forcibly resets a misfeed or malfunction that occurred due to incorrect operation, etc. when it cannot be reset by opening and closing the Front Door and turning ON S1. Ground terminal used for memory clear. Initializes all data except those counted by the electronic counters.

PJ2

TP1 TP2

GND Test Point Memory Clear Test Point

S-4

<Clearing Procedures> D Initialize Points PJ2 1. Turn OFF the Power Switch. 2. With PJ2 closed, turn ON the Power Switch. 3. In approx. 5 sec., open PJ2. D Memory Clear Test Point TP2 1. Turn OFF the Power Switch. 2. With the circuit across TP1 and 2 closed, turn ON the Power Switch. 3. In approx. 5 sec., open the circuit across TP1 and 2.

NOTE D If an erratic operation or display occurs, perform the clearing procedures in the order of PJ2 and TP2. D When memory clear has been performed, make the necessary settings again. <List of Data Cleared by Switches and Points> Clearing Means Data Cleared Misfeed display Malfunction display (excluding Exposure Lamp and fusing malfunctions) Malfunction display (including Exposure Lamp and fusing malfunctions) Erratic operation/display User mode Service mode F3/5/8 adjustment values Adjust mode f : Cleared * : Not cleared Front Door Open/Close f f Trouble Reset Switch (S1) f f Initialize Points (PJ2) f f Memory Clear Test Point (TP2) f f

* * * * * *

f * * * * *

f f * * * *

f f f f f f

S-5

1151SBS0400A

4 USER MODE
D This mode is used to make various settings according to the users needs.
1158SBS0401A

4-1. Functions Available from the User Mode

No.

Function

13 14 20 21 28

Optimum exposure level Priority manual exposure level Auto clear ON/OFF Energy Saver ON timing Auto power OFF timing

1151SBS0402A

4-2. User Mode Setting Procedure

<Setting Procedure> 1. Hold down the Panel Reset key for about 3 seconds to set the copier into the User mode. (U appears on the Zoom Ratio Indicator.) 2. From the 10-Keys, enter the number assigned to the desired function. (The number entered appears following the letter U on the Zoom Ratio Indicator.) 3. Press the Start key. (Then, the current setting for that particular function appears on the Multi-Copy Display.) 4. Press the Clear key. 5. Make a new setting. 6. Press the Start key to validate the entry of the new setting. NOTE: If the setting data entered is outside the specifications, it is not validated and is shown blinking. <Resetting Procedure> D Press the Panel Reset key to return to the Basic screen.

S-6

1158SBS0403A

4-3. User Mode Setting Details

1158SBS040301A

[User Mode]
Function No. U-13 Setting (The default is Highlighted .) <Optimum Exposure Level> Determine the optimum exposure level in the Auto as well as the Manual Exposure mode. Data 46 47 48 49 U-14 Description Low level 4: *2.0 steps Low level 3: *1.5 steps Low level 2: *1.0 steps Low level 1: *0.5 steps Data 50 51 52 Description Standard "0 steps High level 1: +0.5 steps High level 2: +1.0 steps

<Priority Manual Exposure Level> Determine the priority exposure level for the Manual Exposure mode. The level determines the priority exposure level selected when the exposure mode is switched from the initial Auto to Manual, and when Manual Exposure is initially selected when power is turned ON. [Auto " Manual] Data 0 1 2 3 4 5 6 7 8 Description Auto " EXP.1 Auto " EXP.2 Auto " EXP.3 Auto " EXP.4 Auto " EXP.5 Auto " EXP.6 Auto " EXP.7 Auto " EXP.8 Auto " EXP.9 Data 10 11 12 13 14 15 16 17 18 [Manual] Description Manual EXP.1 Manual EXP.2 Manual EXP.3 Manual EXP.4 Manual EXP.5 Manual EXP.6 Manual EXP.7 Manual EXP.8 Manual EXP.9

U-20

<Auto Clear ON/OFF> Select whether or not to activate the auto clear (panel reset) function after the lapse of a given period of time after a copy cycle has been completed or a key on the control panel has been operated. Data Description 0 Disabled 1 Enabled: 30 sec. 2 Enabled: 1 min.

S-7

1158SBS040302A

[User Mode]
Function No. U-21 Setting (The default is Highlighted .) <Energy Saver ON Timing> Select whether or not to set the copier into the Energy Saver mode after the lapse of a given period of time after a copy cycle has been completed or a key on the control panel has been operated. Data 1 2 15 Description Enabled: 1 min. Enabled: 2 min. Enabled: 15 min. Data 97 98 99 Description Enabled: 97 min. Enabled: 98 min. Enabled: 120 min.

NOTE: Except for 99, the setting data equals the time in minutes. U-28 <Auto Power OFF Timing> Select whether or not to enable the auto power OFF function that turns power off automatically after the lapse of a given period of time after a copy cycle has been completed or a key on the control panel has been operated. Data 0 1 2 60 Description Disabled Enabled: 1 min. Enabled: 2 min. Enabled: 60 min. Data 97 98 99 Description Enabled: 97 min. Enabled: 98 min. Enabled: 120 min.

NOTES: 1. Except for 0 and 99, the setting data equals the time in minutes. 2. 0 cannot be selected for this function if C-41 (Auto Power OFF Disabling) available as one of the Tech. Rep. Choice functions is set to 0.

S-8

1151SBS0500A

SERVICE MODE

D This mode is used by the Tech. Rep. to set, check, adjust, and/or program various service functions.
1158SBS0501A

5-1. Service Mode Function Tree

Test Service Mode No. 1

F1 : Paper passage test F2 : PC Drum Charge/Image Transfer Coronas output F3 : Exposure Lamp voltage adjustment F4 : Paper Separator Corona output F5 : AE Sensor automatic adjustment F6 : Edge Erase Lamp check F8 : ATDC Sensor automatic adjustment F9 : IU check, optimum exposure adjustment FA : Scanner/Edge Erase Lamp operation check

Tech. Rep. Choice Service Mode No. 2 Service Mode

C-1 : Size Counter counting C-2 : Total Counter counting C-4 : Maintenance Call Reminder ON/OFF C-5 : PM Counter C-7 : IU 60K stop C-15 : Toner empty stop C-20 : Leading edge erase C-21 : Trailing edge erase C-23 : Loop length adjustment C-41 : Auto power OFF disabling C-90 : ATDC detection level

PM Counter and Ports/Options Counter

Service Mode No. 4

Paper Size Counter

Service Mode No. 5

Misfeed Counter

Service Mode No. 6

Malfunction Counter

Service Mode No. 7

Parts/Supplies Life Counter

Service Mode No. 8

Display

Service Mode No. 0

S-9

1151SBS0502A

5-2. Entering the Service Mode

<Procedure> 1. Perform the following steps to set the copier into the Service mode. Press the Stop key. Press 0. Press the Stop key. Press 1.

2. From the 10-Keys, press the number corresponding to the service mode no. assigned. 3. Perform the necessary steps for the function selected. <Leaving the Service Mode> D Press the Panel Reset key twice to go back to the Basic screen.

S-10

1151SBS0503A

5-3. Settings in the Service Mode

1158SBS050301A

1. Test
D This function allows the Tech. Rep. to perform various functional tests and adjustments. <Setting Procedure> 1. Enter the number assigned to the desired test from the 10-Keys. (The number appears on the MultiCopy Display.) 2. Press the Start key to start the test. 3. Press the Stop key to stop the test. <Test Copy> D A test copy can be made by entering F3, F5 of the Test No., holding down the Stop key and pressing the Start key. <Leaving the Function> D Press the Panel Reset key twice to go back to the Basic screen.

[Service Mode " Test]

Test No. F1 Description <Paper Passage Test> A paper passage test is carried out to check for correct sensor operation without having to wait for the copier to complete warming up. It provides the following two modes: 1. Normal mode (The Zoom Ratio Indicator shows On.) 2. Load OFF mode, in which some parts are put in an inactive state (The Zoom Ratio Indicator shows Off.) <Procedure> 1. Using the Zoom Up/Down key, select either one of the two modes. 2. Press the Start key. <To quit> D Press the Stop key, or the test stops when paper runs out. F2 F3 <PC Drum Charge/Image Transfer Coronas Output> Do not use this test as it is only for factory adjustment. <Exposure Lamp Voltage Adjustment> This test allows the Tech. Rep. to adjust the maximum Exposure Lamp voltage and the optimum exposure setting in the Manual Exposure mode. (It runs for 30 sec.) NOTE For details, see DIS/REASSEMBLY, ADJUSTMENT. F4 F5 <Paper Separator Corona Output> Do not use this test as it is only for factory adjustment. <AE Sensor Automatic Adjustment> This test automatically adjusts the AE Sensor. (It runs for 5 sec.) NOTE For details, see DIS/REASSEMBLY, ADJUSTMENT.

S-11

[Service Mode " Test]

Test No. F6 Description <Edge Erase Lamp Check> This test checks whether the Edge Erase Lamp turns ON and OFF properly. (It runs for one complete copy cycle.) <Procedure> D Press the Start key after the copier has completed warming up. This causes the lamp to make a checkered pattern. F8 <ATDC Sensor Automatic Adjustment> This test automatically adjusts the ATDC Sensor. (It runs for about 5 min.) NOTE For details, see DIS/REASSEMBLY, ADJUSTMENT. F9 FA <IU Check, Optimum Exposure Adjustment> Do not use this test as it is only for factory adjustment. <Scanner/Edge Erase Lamp Operation Check> Do not use this test as it is only for factory adjustment.

Components Energized in the Tests

Test Operation Component Main Drive Motor PC Drum Drive Motor Fan Motors Toner Replenishing Motor HV (PC Drum Charge, Image Transfer, grid) Bias (Developing, Separator, seal) Scanner Paper Take-Up Roll Paper Transport Rollers Synchronizing Rollers Exposure Lamp Main Erase Lamp Edge Erase Lamp PC Drum Paper Separator Fingers Misfeed detection Malfunction detection F1 f f f * * * f f f f * f * f f f F2 f f f * f * * * * * * f * * * f F3 f f f * * f * * * * f f f * * f F4 f f f * * f * * * * * f f * * F5 f f f * * f * * * * f f f * * F6 f f f * f f f f f f f f * f f F8 f f f f f f * * * * * f f * * F9 f f f * f f f * * * f f * * * FA * * * * * * f * * * * * f * *

f f f f f f f : Energized * : Remain deenergized

*F1 : Deenergized in the load OFF mode. *F3/5 : The Scanner stops at the TRON position. *F6 : Turned ON and OFF alternately to make a checkered pattern.

S-12

1158SBS050302A

2. Tech. Rep. Choice

D This function allows the Tech. Rep. to make various settings and adjustments. <Setting Procedure> 1. Press 2 from the 10-Keys. (The Zoom Ratio Indicator shows C.) 2. Press the number assigned to the desired Tech. Rep. Choice. (The Zoom Ratio Indicator shows C plus the number of the chosen function.) 3. Press the Start key. (The Multi-Copy Display shows the current setting for the chosen function.) 4. Clear the current setting using the Clear key and enter the new setting from the 10-Key Pad. 5. Press the Start key to validate the new setting. NOTE: If the setting is illegal, it is not validated and is shown blinking. <Test Copy> D A test copy can be made by entering C of the Tech. Rep. Choice No., holding down the Stop key and pressing the Start key. <Leaving the Function> D Press the Panel Reset key twice to go back to the Basic screen.

[Service Mode " Tech. Rep. Choice]

Choice No. C-1 Setting (The default is Highlighted .) <Size Counter Counting> Select the size of the paper to be counted by the Size Counter. Data Description (Metric areas) Description (Inch areas) 0 1 2 3

No count

A3

A3/B4

A3/B4/FLS 11 x 17, 8-1/2 x 14, 11 x 14

No count

11 x 17

11 x 17, 8-1/2 x 14

NOTE: See the Count-up Table for details. C-2 <Total Counter Counting> Select the conditions (paper size and 2-sided copying) by which the Total Counter count is increased. Data Description 0 1 count per 1 copy cycle 1 Multiple count-up 2 Multiple count-up

NOTE: See the Count-up Table for details.

S-13

[Service Mode " Tech. Rep. Choice]

Choice No. Setting (The default is Highlighted .) <Count-up Table> Copying Size Total Total (mechanical, electronic) Size (electronic) 2-Sided Total (electronic) 2-Sided Size (electronic)
Counting copies Counting copy cycles

1-Sided
Sizes other than those set

2-Sided
Sizes other than those set

Set sizes 0 1 1 Mode 1 2 2 1 0 0 1 1 2 2 2 2 2 2

Set sizes 0 2 2 Mode 1 2 4 2 1 1 4 4 4 0 4 4 4 4

Manual Bypass

Mode 1 2 1 0 0 0 1 1

Mode 1 2 2 0

1 0 0 0 1 1

1 0

1 1

2 2

1 2

Plug-In (mechanical)

0: No count 1: 1 count 2: 2 counts 4: 4 counts C-4 <Maintenance Call Reminder ON/OFF> Select whether to enable or disable the maintenance call reminder. Data Description C-5 0 The maintenance call reminder is not given. 1 The maintenance call reminder is given.

<PM Counter> Select either PM Counter or Copy Kit Counter. Data 0 1 2 Description PM Counter Copy Kit Counter: Copying not inhibited after the counter has counted down to zero. Copy Kit Counter: Copying inhibited after the counter has counted down to zero.

NOTE: If this function is set to 2, the copier gives an indication to replace the IU and inhibits the initiation of a new copy cycle even if C-4 is set to 0.

S-14

[Service Mode " Tech. Rep. Choice]

Choice No. C-7 Setting (The default is Highlighted .) <IU 60K Stop> Select whether or not to inhibit copying when IU Counter has counted 60K. Data Description 0 Permits copying. 1 Inhibits copying.

Default: 0 (inch areas) / 1 (metric areas) C-15 <Toner Empty Stop> Select whether or not to inhibit copying when a toner-empty condition is detected. Data Description 0 Permits copying. 1 Inhibits copying.

NOTE: If 1 is set, the copier inhibits copying when it detects a T/C of 2% or lower. C-20 <Leading Edge Erase> Varies the width of erase on the leading edge. Data Description 0 Smaller width 1 Greater width

NOTE: When the setting is changed, it results in the erase width being changed by about 3 mm. C-21 <Trailing Edge Erase> Varies the width of erase on the trailing edge. Data Description 0 Smaller width 1 Greater width

NOTE: When the setting is changed, it results in the erase width being changed by about 3 mm. C-23 <Loop Length Adjustment> Adjust the length of the loop to be formed in paper before the Synchronizing Rollers. Data 47 48 49 50 Description Loop length about 4.9 mm Loop length about 5.6 mm Loop length about 6.3 mm Loop length about 7.0 mm Data 51 52 53 Description Loop length about 7.7 mm Loop length about 8.4 mm Loop length about 9.1 mm

S-15

[Service Mode " Tech. Rep. Choice]

Choice No. C-41 Setting (The default is Highlighted .) <Auto Power OFF Disabling> Select whether to enable or disable the setting of 0: Disabled for Auto Power OFF Timing available from the User mode. Data Description C-90 0 Disabled 1 Enabled

<ATDC Detection Level> Select the ATDC control level (T/C ratio). Data 48 49 50 Description T/C ratio 4.0 % T/C ratio 4.5 % T/C ratio 5.0 % Data 51 52 53 Description T/C ratio 5.5 % T/C ratio 6.0 % T/C ratio 6.5 %

S-16

1158SBS050303A

3. PM Counter and Ports/Options Counter

D This function shows the counts of the PM Counter (IU) and Ports/Options Counter. The particular port or option is indicated by the corresponding LED of the Misfeed Monitor. The count is shown across the Zoom Ratio Indicator and Multi-Copy Display. NOTE: The PM Counter is indicated by the IU Service Life Indicator LED. Example) Count: 12345 Multi-Copy Display 123 Zoom Ratio Indicator 45

Counting System D PM Counter: Count-down type (When the counter has counted down to zero, a * (minus) sign appears in the Zoom Ratio Indicator and the count is thereafter incremented. D Ports/Options Counter: Count-up type

<Setting Procedure> 1. Select the PM Counter and Ports/Options Counter function. 2. Each press of the Paper Select key lights up a new LED representing the new counter in the following order. Order 1 2 3 Description PM Counter Copier paper source Manual bypass

<Setting a PM Counter Count> 1. Show the count of the PM Counter (IU Service Life Indicator) and clear it. 2. Enter the desired count from the 10-Keys. NOTE Press the Stop key to undo the clearing command. 3. Press the Start key to validate the new count setting. <Clearing a Count> D Show the count of the counter to be cleared and press the Clear key. If a count is mistakenly cleared, press the Stop key to undo the clearing command.

S-17

1158SBS050304A

4. Paper Size Counter

D This function shows the counts of different sizes of paper. The paper size is indicated by the Paper Select LED. The count is shown across the Zoom Ratio Indicator and Multi-Copy Display. Zoom Ratio Indicator 45

Example) Count: 12345

Multi-Copy Display 123

<Setting Procedure> 1. Select the Paper Size Counter function. 2. Each press of the Paper Select key lights up a new LED representing the new counter in the following order. [Metric areas] Order 1 2 3 4 5 Description A3 A4 A5 B4 FLS [Inch areas] Order 1 2 3 4 5 Description Legal Letter 11 x 17 11 x 14 Invoice

<Clearing a Count> D Show the count of the counter to be cleared and press the Clear key. If a count is mistakenly cleared, press the Stop key to undo the clearing command.
1158SBS050305A

5. Misfeed Counter
D This function shows the number of misfeeds that have occurred at different locations in the copier (count-up type counter). The Monitor Display tells the location of the misfeed by a lit LED. The count is shown on the Zoom Ratio Indicator and the misfeed code is given on the Multi-Copy Display. Example) Misfeed location: Manual bypass Count: 123 Zoom Ratio Indicator 123 Multi-Copy Display J

<Setting Procedure> 1. Select the Misfeed Counter function. 2. Each press of the Paper Select key lights up a new LED representing the new counter in the following order.

Order 1 2 3 4 5

Description Manual bypass Copier paper take-up/transport Take-up/transport Separator Exit J0 J0 J1 J2 J3

<Clearing a Count> D Show the count of the counter to be cleared and press the Clear key. If a count is mistakenly cleared, press the Stop key to undo the clearing command.

S-18

1158SBS050306A

6. Malfunction Counter
D This function shows the number of malfunctions that have occurred at different locations in the copier (count-up type counter). The Zoom Ratio Indicator shows the malfunction code, while the Multi-Copy Display shows the count. Example) ATDC Sensor malfunction (F30) Count: 12 Zoom Ratio Indicator F30 Multi-Copy Display 12

<Setting Procedure> 1. Select the Malfunction Counter function. 2. Each press of the Paper Select key shows the count of a new counter in the following order. NOTE: The count is given only if it is not 0. If all counts are 0, the message All 0 is shown. Order 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Malfunction Code 000 010 04C 070 400 500 510 520 600 610 620 F10 F30 E1 E2 Ar1 Description A Main Drive Motor malfunction A PC Drive Moter malfunction A Cooling Fan Motor malfunction A Toner Replenishing Motor malfunction An Exposure Lamp malfunction An abnormally low fusing temperature during warm-up An abnormally low fusing temperature after completion of warm-up An abnormally high fusing temperature A Scanner drive system malfunction A Lens drive system malfunction A Mirror drive system malfunction An AE Sensor malfunction An ATDC Sensor malfunction A starter charging failure An ATDC automatic adjustment/IU fuse blowing failure Copier watchdog

<Clearing a Count> D Show the count of the counter to be cleared and press the Clear key. If a count is mistakenly cleared, press the Stop key to undo the clearing command.

S-19

1158SBS050307A

7. Parts/Supplies Life Counter

D This function shows the number of copy processes to which different parts or supplies have been subjected (count-up type). Each count is given as shown below. Example) IU Counter Count: 1234567 Zoom Ratio Indicator IU Multi-Copy Display 12 Shown alternately 345 67

<Setting Procedure> 1. Select the Parts/Supplies Life Counter function. 2. Each press of the Paper Select key shows the count of a new counter in the following order. Order 1 2 3 4 5 Zoom Ratio Indicator IU Pc St Cb Fu Description IU Counter PC Drum Counter Developer Counter Cleaning Blade Counter Fusing Unit Counter

<Clearing a Count> D Show the count of the counter to be cleared and press the Clear key. If a count is mistakenly cleared, press the Stop key to undo the clearing command. NOTE: The IU Counter cannot be cleared under this function. However, the counts of all counters except the Fusing Unit Counter under this counter function are cleared when the starter charging sequence is completed.

S-20

1158SBS050308A

8.

Display
D This function is used to check the time it takes the copier to complete different functions and to make a control panel display test and sensor check.

<Setting Procedure> 1. Select the Display function. 2. From the 10-Keys, enter the number (0, 1, 2, 6, or 7) corresponding to the item to be checked/set.

[Service Mode " Display]

Display Function d0 Setting <Warm-up time> The warm-up time is shown on the Zoom Ratio Indicator (in units of 100 ms). <First copy time> The first copy time is shown on the Zoom Ratio Indicator (in units of 100 ms). <Multiple copy time> The multiple copy time is shown on the Zoom Ratio Indicator (in units of 100 ms). <Display test> All LEDs on the control panel are turned ON and OFF (blinking) for checking operations. <Sensor check> When a misfeed or malfunction occurs, this function is used to make a sensor check to isolate the possible faulty spot. NOTE For details, see TROUBLESHOOTING.

d1

d2

d6

d7

S-21

1151SBS0600A

ADJUST MODE

D The Adjust mode is used to adjust the optical system at the factory. Use this mode only when the RAM Board (PWB-R) has been replaced and memory clear performed. Whenever PWB-R has been replaced or memory clear performed, be sure to input the values indicated on the Adjust Mode Label on the inside of the Front Door.
1151SBS0601A

6-1. Functions Available in the Adjust Mode

Function Code A0 A1 A2 A3 A4

Name Lens focal length correction Lens full size position correction Mirror full size position correction Feeding-direction zoom ratio correction Full size registration adjustment

Function Code A5 A6 A11 A12 A13

Name Reduction registration adjustment Book-B scan registration adjustment Enlargement registration adjustment Leading edge erase width adjustment Trailing edge erase width adjustment

1151SBS0602A

6-2. Entering the Adjust Mode

<Procedure> 1. Perform the following steps to set the copier into the Service mode. Press the Stop key. Press 0. Press the Stop key. Press 1.

2. Perform the following steps to set the copier into the Adjust mode. Press the Stop key. Press the Start key.

3. From the 10-Keys, press the number corresponding to the adjust mode function to be used. (The function code appears on the zoom ratio indicator.) 4. Press the Start key. Then, the adjustment data appears on the Multi-Copy Display. 5. Using the Clear key, clear the current adjustment data setting and enter the desired data from the 10-Keys. 6. Press the Start key to validate the new data. NOTE: If the setting is illegal, it is not validated and is shown blinking. <Test Copy> D A test copy can be made by entering A of the Adjust Mode No., holding down the Stop key and pressing the Start key. <Leaving the Adjust Mode> D Press the Panel Reset key twice to go back to the Basic screen.

S-22

1151SBS0603A

6-3. Settings in the Adjust Mode [Service Mode " Adjust Mode]
Adjust Mode A0 Lens focal length correction Setting Corrects variations in the Lens focal length (according to the grouping of the Lenses). Data Description 49 Short focal length (*) 50 Standard (0) 51 Long focal length (+)

A1 Lens full size position correction

Corrects the zoom ratio in the crosswise direction by varying the Lens full size position. Data Description 42 .... +26 steps . . . . (Reduction direction) 50 .... +58 steps . . . . 57 +86 steps (Enlargement direction)

A2 Mirror full size position correction

Corrects the optical path length of the Mirror for the Lens focal length. Data Description 42 .... +46 steps . . . . (Reduction direction) 50 .... +110 steps . . . . 57 +166 steps (Enlargement direction)

A3 Feeding-direction zoom ratio correction

Correct the zoom ratio in the feeding direction by varying the scan speed. Data Description 42 .... 3.2% . . . . (Reduction direction) 50 "0% .... .... 58 +3.2% (Enlargement direction)

A4 Full size registration adjustment

Corrects registration between the leading edge of the original and that of the image in the full size mode by varying the Synchronizing Roller start timing. Data Description 30 .... *5.6 mm . . . . (Smaller deviation) 50 "0 mm .... .... 70 +5.6 mm (Greater deviation)

S-23

[Service Mode " Adjust Mode]

Adjust Mode A5 Reduction registration adjustment Setting Corrects registration between the leading edge of the original and that of the image in a reduction mode by varying the Synchronizing Roller start timing. Data Description 30 .... *5.6 mm . . . . (Smaller deviation) 50 "0 mm .... .... 70 +5.6 mm (Greater deviation)

A6 Book-B scan registration adjustment

Corrects the registration between the leading edge of the original and that of the image in Book-B scan by varying the Synchronizing Roller start timing. Data Description 30 .... *5.6 mm . . . . (Smaller deviation) 50 "0 mm .... .... 70 +5.6 mm (Greater deviation)

A11 Enlargement registration adjustment

Corrects registration between the leading edge of the original and that of the image in an enlargement mode by varying the Synchronizing Roller start timing. Data Description 30 .... *5.6 mm . . . . (Smaller deviation) 50 "0 mm .... .... 70 +5.6 mm (Greater deviation)

A12 Leading edge erase width adjustment

Corrects the leading edge erase width by varying the Image Erase Lamp ON timing. Data Description 42 .... *6 mm . . . . (Smaller width) 50 "0 mm .... .... 58 +6 mm (Greater width)

A13 Trailing edge erase width adjustment

Corrects the trailing edge erase width by varying the Image Erase Lamp ON timing. Data Description 40 .... *7.2 mm . . . . (Smaller width) 50 "0 mm .... .... 60 +7.2 mm (Greater width)

S-24

1151SBS0700A

FUNCTION SETTING REQUIREMENTS AT REPLACEMENT OF PARTS

D If a part is replaced as part of troubleshooting and other service jobs, some parts require that a Test operation be run and data values reentered and/or cleared. Replacement Part Function Memory clear Initialize Job program User mode Tech. Rep. Choice Test F3 Test F5 Test F8 PM Counter Service mode Clearing Parts/ Supplies Life Counter Pc Clearing Parts/ Supplies Life Counter St Clearing Parts/ Supplies Life Counter Cb Clearing Parts/ Supplies Life Counter Fu Adjust mode f f : Required f

RAM Board f f f f f f f f

IU

PC Drum

Developer *1

Cleaning Blade

Fusing Rollers

Exposure Lamp *2

f f f f f f

*1 : Including the replacement of the ATDC Sensor *2 : Including the cleaning of Lamp Regulator and optical system.

S-25

DIS/REASSEMBLY, ADJUSTMENT

1151SBD0000A

u For the Utmost safety u

! Warning
D For replacement parts, use the genuine parts with their part numbers specified in the parts manual. Use of a wrong part could cause an overload or dielectric breakdown, resulting in an electric shock or fire. D Replace a blown fuse or thermal fuse with the corresponding genuine part with its part number specified in the parts manual. Use of a fuse with a different rating or one with the same rating but of a different type can result in a fire. Especially when a thermal fuse blows frequently, the thermal control system is probably faulty. Be sure to take necessary action. D Before attempting to disassemble the machine, be sure to unplug its power cord. The machine contains a high voltage unit and a circuit with a large current capacity that may cause an electric shock or burn from sparking. The machine also contains quick moving parts, which could injure a person. If the machine uses a laser, a person can lose his/her eyesight by a laser beam leak. D Wherever feasible, keep the covers and parts mounted when energizing the machine. If it is absolutely necessary to energize the machine with its cover removed, do not touch an exposed part that is being charged and use care not to allow your clothing to be caught by a timing belt, gear, or other moving part. D Do not leave the machine unattended while it is being energized.

! Caution
D To actuate an interlock switch with a cover removed or opened, be sure to use the interlock switch actuating jig. Use of folded paper can damage the interlock switch mechanism.

! Caution
D A high voltage is being applied to the part marked with the symbol shown on the right. Touching it can cause an electric shock. Be sure to unplug the power cord when servicing this part or other parts near it. D When the machine is energized with any of its covers removed, never use a flammable spray near it, as a fire can result. D Make sure that correct screws (diameter and length of the screw, binding/tapping screws) are used in the correct places when assembling parts. If a wrong screw is used, a short insulating distance could result. It could also result in collapsed threads, which provides only a poor grounding connection, resulting in an electric shock. D A toothed washer and spring washer, if used originally, must be reinstalled. If they are left out, a contact failure results, causing an electric shock or fire. D Replace a lithium cell only with one having the part number specified in the parts manual. An explosion could result if the cell is installed with wrong polarity or a wrong cell is installed. Dispose of a used lithium cell according to the applicable local regulations. Never throw it away or abandon it on the users premises.

u Other Precautions u
D While the machine is being energized, do not unplug or plug in a connector on a PWB or relay harness. D Since the Magnet Roller of the Imaging Unit generates a strong magnetic force, do not bring a CRT, watch, floppy disk, or magnetic card near it. D Use of an air gun or vacuum generates static electricity which can cause the ATDC Sensor and associated parts to break down. Be sure therefore to use a blower brush or cloth to clean these parts. If a unit is to be cleaned, be sure to remove the sensors in advance. D MOS lCs are susceptible to static electricity. When handling a PWB loaded with MOS ICs, follow precautions given in 1-2. INSTRUCTIONS FOR HANDLING THE PWBs WITH MOS ICs. D The PC Drum is highly delicate. When handling the PC Drum, follow the precautions given in 1-3. HANDLING OF THE PC DRUM. D To reassemble, reverse the order of disassembly unless otherwise specified. D Note that replacement of a PWB may call for readjustments or resetting of particular items. CAUTION: DANGER OF EXPLOSION IF BATTERY IS INCORRECTLY REPLACED. REPLACE ONLY WITH THE SAME OR EQUIVALENT TYPE RECOMMENDED BY THE MANUFACTURER. DISPOSE OF USED BATTERIES ACCORDING TO THE MANUFACTURERS INSTRUCTIONS.

ADVARSEL!:Lithiumbatteri - Eksplosionsfare ved fejlagtig hndtering. Udskiftning m kun ske med batteri af samme fabrikat og type. Levr det brugle bafferi tilbage til leverandoren.

ii

1158SBD000BA

CONTENTS
1 SERVICE INSTRUCTIONS 1-1. PRECAUTIONS FOR DISASSEMBLY/ADJUSTMENTS . . . . . . 1-2. INSTRUCTIONS FOR HANDLING THE PWBs WITH MOS ICs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3. HANDLING OF THE PC DRUM . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4. PARTS WHICH MUST NOT BE TOUCHED . . . . . . . . . . . . . . . . 2 DISASSEMBLY/REASSEMBLY 2-1. DOORS, COVERS, AND EXTERIOR PARTS: IDENTIFICATION AND REMOVAL PROCEDURES . . . . . . . . . 2-2. REMOVAL OF PWBs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3. BELT INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4. PAPER TAKEUP/TRANSPORT SECTIONS . . . . . . . . . . . . . . . (1) Removal of the Paper Take-Up Unit . . . . . . . . . . . . . . . . . . . . . (2) Removal of the Paper Take-Up Rolls . . . . . . . . . . . . . . . . . . . . (3) Cleaning of the Paper Take-Up Rolls . . . . . . . . . . . . . . . . . . . . (4) Removal of the Suction Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . (5) Disassembly of the Suction Unit . . . . . . . . . . . . . . . . . . . . . . . . (6) Disassembly of the Multi Bypass Table (Option) . . . . . . . . . . 2-5. OPTICAL SECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (1) Removal of the Lens Drive Cable . . . . . . . . . . . . . . . . . . . . . . . (2) Winding of the Lens Drive Cable . . . . . . . . . . . . . . . . . . . . . . . (3) Removal of the Scanner Drive Cable . . . . . . . . . . . . . . . . . . . . (4) Winding of the Scanner Drive Cable . . . . . . . . . . . . . . . . . . . . (5) Removal of the Scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (6) Cleaning of the Exposure Lamp . . . . . . . . . . . . . . . . . . . . . . . . (7) Cleaning of the 1st/2nd/3rd Mirrors . . . . . . . . . . . . . . . . . . . . . (8) Cleaning of the Lens and 4th Mirror . . . . . . . . . . . . . . . . . . . . . (9) Cleaning of the Optical Section Cooling Fan Filter . . . . . . . . 2-6. IMAGING UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (1) Disassembly, Cleaning, Replacement and Starter changing of the Imaging Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . D Replacement of the PC Drum . . . . . . . . . . . . . . . . . . . . . . . . D Replacement of the Toner Scattering Prevention Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D Replacement of the Cleaning Blade . . . . . . . . . . . . . . . . . . . D Cleaning of the PC Drum Paper Separator Fingers . . . . . . D Cleaning of the Ds Positioning Collars . . . . . . . . . . . . . . . . . D Cleaning of the Paper Dust Remover . . . . . . . . . . . . . . . . . . D-1 D-2 D-2 D-4

D-5 D-8 D-10 D-11 D-11 D-12 D-12 D-12 D-12 D-13 D-18 D-18 D-19 D-20 D-22 D-24 D-24 D-25 D-25 D-25 D-26 D-26 D-26 D-26 D-27 D-28 D-28 D-28

iii

CONTENTS
D Replacement of the Toner Antispill Mylar . . . . . . . . . . . . . . . D Cleaning of the Upper Pre-Image Transfer Guide Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D Cleaning of the Magnet Roller Lower Filter . . . . . . . . . . . . . (2) Cleaning of the Main Erase Lamp . . . . . . . . . . . . . . . . . . . . . . (3) Cleaning of the Edge Erase Lamp . . . . . . . . . . . . . . . . . . . . . . 2-7. PC DRUM CHARGE CORONA/IMAGE TRANSFER CORONA UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (1) Cleaning of the PC Drum Charge Corona Housing . . . . . . . . (2) Cleaning of the PC Drum Charge Corona Grid Mesh . . . . . . (3) Cleaning of the Comb Electrode . . . . . . . . . . . . . . . . . . . . . . . . (4) Cleaning of the Image Transfer/Paper Separator Coronas Wires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (5) Cleaning of the Image Transfer/Paper Separator Coronas Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (6) Cleaning of the Lower Pre-Image Transfer Guide Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (7) Replacement of the Ozone Filter . . . . . . . . . . . . . . . . . . . . . . . 2-8. Fusing Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (1) Removal of the Fusing Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . (2) Cleaning of the Pre-Fusing Guide Plate . . . . . . . . . . . . . . . . . (3) Removal of the Upper Fusing Roller . . . . . . . . . . . . . . . . . . . . (4) Cleaning of the Upper Fusing Roller . . . . . . . . . . . . . . . . . . . . (5) Cleaning of the Upper Paper Separator Fingers . . . . . . . . . . (6) Cleaning of the Fusing Thermistor . . . . . . . . . . . . . . . . . . . . . . (7) Removal of the Lower Fusing Roller . . . . . . . . . . . . . . . . . . . . (8) Cleaning of the Lower Fusing Roller . . . . . . . . . . . . . . . . . . . . (9) Cleaning of the Lower Paper Separator Fingers . . . . . . . . . . (10) Removal of the Oil Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (11) Cleaning of the Oil Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ADJUSTMENT 3-1. JIGS AND TOOLS USED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2. ADJUSTMENT REQUIREMENTS LIST . . . . . . . . . . . . . . . . . . . . 3-3. ADJUSTMENT OF SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . (1) Adjustment of Front Door Interlock Switch S21 . . . . . . . . . . . 3-4. ELECTRICAL/IMAGE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . (1) Adjustment of the Maximum Exposure Lamp Voltage for the Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (2) Adjustment of the Optimum Exposure Setting in the Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (3) Adjustment of the Optimum Exposure Setting in the Auto Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-40 D-41 D-42 D-43 D-44 D-44 D-47 D-48 D-28 D-29 D-29 D-30 D-30 D-32 D-32 D-32 D-33 D-33 D-33 D-34 D-34 D-34 D-34 D-35 D-35 D-37 D-37 D-37 D-38 D-38 D-38 D-39 D-39

iv

CONTENTS
(4) Adjustment of the ATDC Sensor . . . . . . . . . . . . . . . . . . . . . . . . (5) Adjustment of the Aperture Blades . . . . . . . . . . . . . . . . . . . . . . (6) Adjustment of the Multi Bypass Table Reference Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (7) Adjustment of the 1st Drawer Reference Position . . . . . . . . . (8) Adjustment of the Leading Edge Registration . . . . . . . . . . . . . D Full Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D Enlargement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D Reduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (9) Adjustment of the Image Leading Edge Erase Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (10) Adjustment of the Edge Erase Lamp Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5. OTHER ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (1) Adjustment of the Scanner/Mirrors Carriage Position . . . . . . (2) Adjustment of the Gap Between the Doctor Blade and Sleeve Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (3) Adjustment of the PC Drum Paper Separator Fingers Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 MISCELLANEOUS 4-1. INSTALLATION OF THE PLUG-IN COUNTER MOUNTING BRACKET (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-63 D-49 D-50 D-51 D-52 D-53 D-53 D-55 D-56 D-57 D-59 D-60 D-60 D-61 D-62

1139SBD0100A

SERVICE INSTRUCTIONS

1151SBD0101A

1-1. PRECAUTIONS FOR DISASSEMBLY/ADJUSTMENTS

Observe the following precautions whenever servicing the copier. D Be sure to unplug the copier from the outlet before attempting to service the copier. D The basic rule is not to operate the copier anytime during disassembly. If it is absolutely necessary to run the copier with its covers removed, use care not to allow your clothing to be caught in revolving parts such as the timing belt and gears. D Be sure to use the Interlock Switch Actuating Jig whenever it is necessary to actuate the Interlock Switch with the covers left open or removed. D Do not plug in or unplug print jacks on the Board or connect or disconnect the Board connectors while power is being supplied to the copier. D Do not use flammable spray around the copier in operation. D The Magnet Roller of the Imaging Unit generates strong magnetic force. Do not bring it near a cathode-ray tube or watch. D The lithium cell in RAM Board PWB-R can burst. At replacement, make sure of the correct polarity and do not change it or create a closed circuit. A used lithium cell should be disposed of according to the local regulations and never be discarded casually or left unattended at the users premises. D Do not use an air gun or vacuum cleaner for cleaning the ATDC Sensor and other sensors, as they can cause electrostatic destruction. Use a blower brush and cloth. If a unit containing these sensors is to be cleaned, first remove the sensors from the unit. D When handling the PWBs with MOS ICs, observe Instructions for Handling the PWBs with MOS ICs. D When handling the PC Drum, observe precautions given in Handling of the PC Drum. D Note that replacement of a PWB may call for readjustments or resetting of particular items. D Use the right screw in the right place at reassembly. Note that some are longer and some are thicker than others. D A toothed washer is used with the screw that secures the ground wire to ensure positive conduction. Do not forget to insert this washer at reassembly. D To reassemble the copier, reverse the order of disassembly unless otherwise specified. D If it becomes necessary to replace the thermal fuse or any other fuse mounted on a board, be sure to use one of the rating marked on the blown fuse. Always note the rating marked on the fuse, as the rating and mounting site or number used are subject to change without notice. D Do not pull out the Toner Hopper while the Toner Bottle is turning, as a damaged Toner Replenishing Motor or locking mechanism could result. If the copier is to be run with the Front Door swung down, make sure that the Toner Hopper is in the locked position. CAUTION: DANGER OF EXPLOSION IF BATTERY IS INCORRECTLY REPLACED. REPLACE ONLY WITH THE SAME OR EQUIVALENT TYPE RECOMMENDED BY THE MANUFACTURER. DISCARD USED BATTERIES ACCORDING TO THE MANUFACTURERS INSTRUCTIONS.

D-1

1139SBD0102A

1-2. INSTRUCTIONS FOR HANDLING THE PWBs WITH MOS ICs

The following precautions must be observed when handling P.W. Boards with MOS (Metal Oxide Semiconductor) ICs. During Transportation/Storage: D During transportation or when in storage, new P.W. Boards must not be indiscriminately removed from their protective conductive bags. D Do not store or place P.W. Boards in a location exposed to direct sunlight. D When it becomes absolutely necessary to remove a Board from its conductive bag or case, always place it on its conductive mat in an area as free as possible from static electricity. D Do not touch the pins of the ICs with your bare hands. During Replacement: D Before unplugging connectors from the P.W. Boards, make sure that the power cord has been unplugged from the outlet. D When removing a Board from its conductive bag or conductive case, do not touch the pins of the ICs or the printed pattern. Place it in position by holding only the edges of the Board. D Before plugging connectors into the Board, make sure that the power cord has been unplugged from the power outlet. During Inspection: D Avoid checking the IC directly with a multimeter; use connectors on the Board. D Never create a closed circuit across IC pins with a metal tool. D When it is absolutely necessary to touch the ICs and other electrical components on the Board, be sure to ground your body.
1151SBD0103A

1-3. HANDLING OF THE PC DRUM

During Transportation/Storage: D Use the specified carton whenever moving or storing the PC Drum. D The storage temperature is in the range between 20C and +40C. D In summer, avoid leaving the PC Drum in a car for a long time. Handling: D Ensure that the correct PC Drum is used. D Whenever the PC Drum has been removed from the copier, store it in its container or protect it with a Drum Cloth. D The PC Drum exhibits greatest light fatigue after being exposed to strong light over an extended period of time. Never, therefore, expose it to direct sunlight. D Use care not to contaminate the surface of the PC Drum with oil-base solvent, fingerprints, and other foreign matter. D Do not scratch the surface of the PC Drum. D Do not apply chemicals to the surface of the PC Drum. D Do not attempt to wipe clean the surface of the PC Drum.

D-2

If, however, the surface is contaminated with fingerprints, clean it using the following procedure. 1. Place the PC Drum into one half of its container.

2. Gently wipe the residual toner off the surface of the PC Drum with a dry, Dust-Free Cotton Pad. a) Rotate the PC Drum so that the area of its surface on which the line of toner left by the Cleaning Blade is present is facing straight up. Wipe the surface in one continuous movement from the rear edge of the PC Drum to the front edge and off the surface of the PC Drum. b) Rotate the PC Drum slightly and wipe the newly exposed surface area with a CLEAN face of the Dust-Free Cotton Pad. Repeat this procedure until the entire surface of the PC Drum has been thoroughly cleaned. * At this time, always use a CLEAN face of the dry Dust-Free Cotton Pad until no toner is evident on the face of the Pad after wiping. 3. Soak a small amount of either ethyl alcohol or isopropyl alcohol into a clean, unused Dust-Free Cotton Pad which has been folded over into quarters. Now, wipe the surface of the PC Drum in one continuous movement from its rear edge to its front edge and off its surface one to two times. * Never move the Pad back and forth.

4. Using the SAME face of the Pad, repeat the procedure explained in the latter half of step 3 until the entire surface of the PC Drum has been wiped. Always OVERLAP the areas when wiping. Two complete turns of the PC Drum would be appropriate for cleaning.

NOTES D The Organic Photoconductor Drum is softer than CdS and Selenium Drums and is therefore susceptible to scratches. D Even when the PC Drum is only locally dirtied, wipe the entire surface. D Do not expose the PC Drum to direct sunlight. Clean it as quickly as possible even under interior illumination. D If dirt remains after cleaning, repeat the entire procedure from the beginning one more time.

D-3

1151SBD0104A

1-4. PARTS WHICH MUST NOT BE TOUCHED (1) Screws

Purpose of Application of Red Paint Red paint is applied to the screws which cannot be readjusted, set, or reinstalled in the field. The basic rule is not to remove or loosen the screws to which red paint is applied. In addition, be advised that, if two or more screws are designated as those which must not be touched on a single part, only one representative screw may be marked with red paint.

(2) Variable Resistors on Board

Do not turn the variable resistors on boards for which no adjusting instructions are given in ADJUSTMENT.

(3) Other Screws

Lower Pre-Image Transfer Guide Plate (2 screws) Lens Rail height setting screws (2)

1151D042AA

D-4

DISASSEMBLY/REASSEMBLY
MOVAL PROCEDURES
<OPTION>

2-1. DOORS, COVERS, AND EXTERIOR PARTS: IDENTIFICATION AND RE-

8 6 5 4 3 2 1 13 12 12 7 8 9 10 9

10 11

14 15 14
1158D017AA

1158D018AA

18

19 17 20 21 16

22 23 24
1158D019AA

D-5

No. 1

Part Name Front Door

Removal Procedure Swing down No.1. Remove one screw that secures the Belt. Remove two screws that secure the Front Door (only on one side). Slide the Door to the side from which the screws have been removed. Swing down No.1. Remove No.9. Release and swing up the Upper Half of the copier. Remove No.21. Remove two screws that secure the control panel and loosen another five screws that secure the control panel. Remove two screws that secure the Scales. Remove the Original Cover. Release and swing up the Upper Half of the copier. Remove the Screw Cover and one mounting screw of No.5. Remove the Original Cover. Remove one screw that secures the Left Hinge Cover. Remove the Original Cover. Remove No.6, 8 and 9. Remove one screw that secures No.7. Remove No.11. secure No.10. Remove No.9. Remove two screws that

Control Panel

3 4 5

Original Scales Original Glass Rear Upper Cover (Small) Left Hinge Cover Rear Upper Cover Right Hinge Cover Upper Right Cover Right Cover Middle Right Cover Right Door Multi Bypass Table Mounting Bracket Counter Cover 1st Drawer Rear Cover Upper Rear Cover

6 7 8 9 10 11 12 13 14 15 16 17

Remove four screws that secure No.11. Open No.12 and remove it by lifting it up. Remove two screws that secure the Multi Bypass Table Mounting Bracket. Remove No.14 by snapping if off. Slide out the Drawer and remove one screw that secures the Stopper at the rear left corner. Swing down No.1. Release and swing up the Upper Half of the copier. Remove two screws that secure the Rear Cover. Swing down No.1. Release and swing up the Upper Half of the copier. Remove three screws that secure the Upper Rear Cover.

18

Original Cover

Remove the Original Cover by pulling it up.

D-6

No. 19

Part Name Upper Left Cover

Removal Procedure Swing down No.1. Release and swing up the Upper Half of the copier. Remove four screws that secure the Upper Left Cover. Swing down No.1. Release and swing up the Upper Half of the copier. Remove one screw that secures the Middle Front Left Cover. Swing down No.1. Release and swing up the Upper Half of the copier. Remove No.22. Remove one screw that secures the Front Exit Cover. Swing down No.1. Release and swing up the Upper Half of the copier. Remove No.26. Remove one screw that secures the Rear Exit Cover. Remove two screws that secure the Lower Left Cover. Swing down No.1. Release and swing up the Upper Half of the copier. Remove one screw that secures the Middle Rear Left Cover.

20

Middle Front Left Cover

21

Front Exit Cover

22

Rear Exit Cover

23 24

Lower Left Cover Middle Rear Left Cover

D-7

2-2. REMOVAL OF PWBs

D When removing a PWB, first go over PRECAUTIONS FOR HANDLING THE PWBs contained in SWITCHES ON PWBs and use the removal procedures given on the next page. D Replacement of a PWB may call for readjustments or resetting of particular items. D The removal procedures given on the next page omit the steps to unplug connectors and remove the PWB from the PWB support.

PWB-D

PWB-C

PU2

D-8

Symbol PWB-A PWB-C PWB-D PWB-E PWB-H PWB-P

Name Master Board Power Supply Board Noise Filter Board Motor Drive Board AE Sensor Board Control Panel

Removal Procedure Open 1. Release and swing up the Upper Half of the copier. Remove 19. Open 1. Release and swing up the Upper Half of the copier. Remove 17, 18, and 19. Remove four screws that secure the Power Supply Unit Cover. Open 1 and 12. Remove 3 and 4. Remove 9, 10, and 11. Remove the optical cover.

Open 1. Remove 9. Release and swing up the Upper Half of the copier. Remove 21. Remove seven screws that secure Control Panel. Open 1. Release and swing up the Upper Half of the copier. Remove 19. Open 1 and 12. Remove 9, 10, and 11.

PWB-R PU1 PU2 HV1 UN3

RAM Board Power Supply Unit DC Power Supply Unit High Voltage Unit ATDC Sensor

Open 1. Release and swing up the Upper Half of the copier. Remove 17 and 18. Open 1. Release and swing up the Upper Half of the copier. Remove 19. Remove PWB-A. Open 1. Release and swing up the Upper Half of the copier. Take out the I/U. Remove two screws that secure the Synchronizing Roller Guide Unit.

z Details of Readjustments/Resetting Involved In Replacement of PWB-R, and UN3. D When PWB-R is replaced: Carry out Memory Clear and then make the Tech. Rep. Program, Users Choice, and Adjust settings again. D When UN3 is replaced: Discard the developer which had been used until UN3 was replaced, charge the Developing Unit with fresh starter, and adjust ATDC.

D-9

2-3. BELT INSTALLATIONS

D Rear View

Drive/Suction Unit

1151D052AB

Paper Take-Up Unit

1142D005AA

D-10

2-4. PAPER TAKE-UP/TRANSPORT SECTIONS (1) Removal of the Paper Take-Up Unit
1. Remove the Multi Bypass Table. (OPTION) See p. D-13. (NO 1 ~ 7) 2. Slide out the 1st Drawer.

1158D021AA

3. Press the tabs at the two places indicated by the arrow and, at the same time, remove the cover.

1142D007AA

4. Remove five screws and the Paper Take-Up Unit.

1158D024AA

5. Unplug the one connector from the solenoids on the Paper Take-Up Unit.

1158D022AA

6. 7. 8. 9.

Remove the Rear and Rear Upper covers. Remove the DC Power Supply Unit. Remove the harness from the wiring saddle. Unplug the one connector.

1158D023AA

D-11

(2) Removal of the Paper Take-Up Rolls

1. Remove one screw to remove the Paper Take-Up Roll.

(3) Cleaning of the Paper Take-Up Rolls

1. Remove the Paper Take-Up Unit from the copier. 2. Using a soft cloth dampened with alcohol, wipe clean the Paper Take-Up Rolls.

(4) Removal of the Suction Unit

1. Remove the Fusing Unit. (See p. D-34.) 2. Unplug the Suction Fan connector and remove the wire from the clamp.

1151D029AA

3. Remove four screws to remove the Suction Unit.

1151D030AA

(5) Disassembly of the Suction Unit

1. Remove the four Suction Drive Rolls and six bushings by pulling them in the direction of the arrow.

1151D004AA

D-12

2. Snap off the three E-rings from the Suction Drive Unit. 3. Remove the gear and bushings.

4. Remove the Pre-Fusing Guide Plate. 5. Remove the Suction Drive Unit.

1151D005AA

6. Remove the four belts.

1151D006AA

7. Remove the Suction Fan.

1151D009AA

(6) Disassembly of the Multi Bypass Table (OPTION)

1. Remove the Right Door.

D-13

2. Remove three screws and the Large Cover.

3. Remove one screw and the Small Cover.

4. Remove three screws and the Guide Lever Unit.

5. Remove four screws and the Multi Bypass Table. 6. Unplug the Multi Bypass Table connector.

D-14

7. Remove one screw and the Multi Bypass Table.

8. Unplug one connector. 9. Remove the Tension Unit.

1151D018AA

10. Remove two screws and the Clutch Mounting Bracket.

11. Remove two screws and the Lower Guide.

12. Remove four screws and the Separator Guide Plate Unit.

D-15

NOTE When reinstalling the Separator Guide Plate Unit, press the parts shown on the left up against the copier frame (both at front and rear).

13. Remove two screws and the Lever.

14. Snap off one C-clip and remove the Separator Unit. NOTE D Please use tweezers when reinstalling the C-clip.

15. Snap off one C-clip and remove the Separator Roll Assy.

16. Remove three screws and the Solenoid Mounting Bracket.

D-16

17. Unplug one solenoid connector. 18. Unplug one photosensor connector and remove the harness from the clamp.

NOTE When reinstalling the Solenoid Mounting Bracket, make sure that the Solenoid is in the deenergized position.

19. Snap off the two C-clips to remove the Paper Take-Up Roll Unit.

20. Snap off the three C-clips to remove the Paper Feed Roll.

21. Snap off one C-clip and remove the Paper Take-Up Roll.

D-17

2-5. OPTICAL SECTION (1) Removal of the Lens Drive Cable

1. Remove two screws and the Optical Section Cover.

2. Remove three screws and the Lens Cover.

3. Remove two screws, two clamps and the Lens Motor Unit.

4. Remove one screw and the Cable Fixing Bracket. 5. Remove the spring.

6. Remove the Cable Drive Gear and the Lens Drive Cable.

D-18

(2) Winding of the Lens Drive Cable

1. Hold the Cable Drive Gear in position with its Bead at the bottom.

2. Wind the shorter length of the Cable three turns clockwise around the Cable Drive Gear, working from the back to the front side. Then tape it.

3. Wind the longer length of the Cable five turns counterclockwise around the Cable Drive Gear, working from the front to back side. Then tape it.

4. Slide the Cable Drive Gear onto its shaft and insert a wrench into the hole to position the Cable Drive Gear.

5. Pass the longer length of the Cable through the U-shaped hole in the Light Blocking Plate and wind it around the Pulley farther away from the Cable Drive Gear.

D-19

6. Temporarily secure the longer length of the Cable to the Cable Fixing Bracket, ensuring a distance of 5 2 mm for the dimension shown on the left.

7. Wind the shorter length of the Cable around the Pulley which is nearer to the Cable Drive Gear.

8. Hook the spring onto the shorter length of the Cable and pull it to hook onto the longer length of the Cable. 9. Check that the dimension noted in step 6 above measures 5 2 mm. Then, secure the Cable Fixing Bracket. 10. Remove the wrench and peel off the two pieces of tape.

(3) Removal of the Scanner Drive Cable

D Remove the Original Cover, Original Scales, and Original Glass. D Remove the Middle Right, Upper Right, Right, Upper Left, and Upper Rear Covers. D Remove the Left and Right Hinge Covers, Rear Upper Cover (Small), and Rear Upper Cover. 1. Align the Scanner with the rectangular hole in the upper copier frame and remove the screw from the Scanner Fixing Bracket. 2. Remove the Fixing Bracket.

3. Unhook the spring to remove the shorter length of the Cable.

D-20

4. Move the 2nd/3rd Mirrors Carriage toward the Scanner Drive Gear so that the Cable slacks off and then remove the longer length of the Cable. 5. Remove four screws and PWB-A.

6. Remove three screws and the Scanner Motor Mounting Bracket. 7. Snap off one E-ring and remove the Scanner Drive Gear.

1151D032AA

8. Remove two screws and the Pulley. 9. Remove the Cable.

D-21

(4) Winding of the Scanner Drive Cable

z Remark Whenever the Scanner Drive Cable has been rewound, be sure to make the Adjustment of the Scanner/ Mirrors Carriage Position. See p. D-60.

Pulley B Pulley A

Scanner Drive Gear

Pulley C

1. Fit the Pulley to the Scanner Drive Gear using two screws.

2. Wind the shorter length of the Cable 2 turns clockwise around the Pulley, working from the back to front side.

3. Wind the longer length of the Cable 5-3/4 turns counterclockwise around the Pulley, working from the front to back side. Then, slip the Cable Holding Jig onto the Pulley.

D-22

4. Fit the Scanner Drive Gear onto the Scanner Motor Mounting Bracket using one E-ring. 5. Secure the Scanner Motor Mounting Bracket to the frame using three screws.

1151D032AA

6. Insert a wrench into the holes in the Scanner Drive Gear and the frame to position the Gear.

1151D033AA

7. Wind the longer length of the Cable around Pulleys C and B and then secure it to the frame.

NOTE Wind the longer length of the Cable around the lower groove in Pulley B (of the two grooves). Position the terminal of the Cable as illustrated on the left.

8. Wind the shorter length of the Cable around Pulleys A and B. NOTE Wind the shorter length of the Cable around the upper groove in Pulley B (two grooves).

D-23

9. Fit the Cable into the groove in the Wire Guide and hook the spring. 10. Remove the wrench and Cable Holding Jig.

(5) Removal of the Scanner

1. Turn the Scanner Drive Gear to move the Scanner to the right-hand side of the copier. Then, remove three screws and the Scanner.

1151D019AA

(6) Cleaning of the Exposure Lamp

1. Remove two screws and the Exposure Lamp Terminal. 2. Slide out the Exposure Lamp.

1151D021AA

3. Using a soft cloth dampened with alcohol, clean the Lamp by wiping its surface gently in one direction. NOTE When reinstalling the Lamp, use care not to allow the protruding navel of the Lamp to hit against the Lamp Reflector and that the protruding navel points toward the opening in the Lamp Reflector.
1076D131

D-24

(7) Cleaning of the 1st/2nd/3rd Mirrors

1. Turn the Scanner Drive Gear to move the Scanner away from the Mirrors. Then, wipe clean the 1st/2nd/3rd Mirrors with a soft cloth. NOTE An alcohol-dampened cloth may be used if the Mirror is seriously contaminated.

(8) Cleaning of the Lens and 4th Mirror

1. Gently dust off the surface of the Lens and 4th Mirror by using a dry soft cloth. NOTE An alcohol-dampened cloth may be used if the Lens or Mirror is seriously contaminated.

(9) Cleaning of the Optical Section Cooling Fan Filter

1. Unhook the Fan Cover at the bottom by slightly raising and, at the same time pulling, the two catches on the bottom.

2. Clean the Filter with a brush or a vacuum cleaner.

D-25

2-6. Imaging Unit (1) Disassembly, Cleaning, Replacement and Starter Changing of the Imaging Unit
1. Remove the Imaging Unit from the copier. 2. Remove two screws and the Imaging Unit Cover.

1151D044AA

3. Remove one screw and the PC Drum Charge Corona Unit.

Replacement of the PC Drum 4. Remove two screws and one Drum Pin to remove the PC Drum. NOTE Whenever the PC Drum has been replaced, be sure to make the Adjustments of the Optimum Exposure Setting in the Manual and Auto Mode. See pp. D-47 to D-48.

Replacement of the Toner Scattering Prevention Plate 5. Remove one screw, one shoulder screw and the Toner Scattering Prevention Plate.

6. Tilt the Developing Unit to remove the developer.

D-26

Replacement of the Cleaning Blade 7. Remove two screws and the Lid.

8. Remove the spring. 9. Remove two screws, one spring, one cap and the Cleaning Blade. Replace it with a new one. NOTE When the Cleaning Blade has been replaced, apply toner to the entire surface of the new Cleaning Blade.

Applying Toner to Cleaning Blade Apply toner to the entire surface of the Cleaning Blade. (Do not forget to coat the surfaces on both ends.)

Install the PC Drum.

Apply a thin coat of toner to the PC Drum.

Turn the PC Drum 1/2 turns backward, then turn it one complete turn forward.

D-27

Cleaning of the PC Drum Paper Separator Fingers 10. Using a soft cloth dampened with alcohol, wipe clean the Paper Separator Fingers.

Cleaning of the Ds Positioning Collars 11. Using a soft cloth dampened with alcohol, wipe clean the Ds Positioning Collars.

Cleaning of the Paper Dust Remover 12. Remove two screws, two compression coil springs and the Synchronizing Roller Unit. NOTE When removing the Synchronizing Roller Unit, use care not to lose the compression coil springs. At reinstallation, fit the close-coiled end of the springs to the bosses on the Imaging Unit.

13. Remove the Synchronizing Roller. 14. Using a brush, whisk the dust and dirt off the Filter.

Replacement of the Toner Antispill Mylar 15. Remove two screws and the Bias Seal. (No Bias Seals are mounted in the copiers for the U.S.A., Canada, and Europe.) 16. Remove two screws and the Toner Antispill Mylar and replace the Mylar.

D-28

NOTE At reinstallation, press the Toner Antispill Mylar up against the Imaging Unit Housing and the rear side of the copier (in the directions of the arrows) and press the Bias Seal up against the Imaging Unit Housing and the front side of the copier (in the directions of the arrows).

Cleaning of the Upper Pre-Image Transfer Guide Plate 17. Remove two screws and the Upper Pre-Image Transfer Guide Plate.

18. Using a brush, whisk toner and dust off the surface of the Upper Pre-Image Transfer Guide Plate.

Cleaning of the Magnet Roller Lower Filter 19. Using a brush, whisk toner and dust off the Magnet Roller Lower Filter. (No Magnet Roller Lower Filters are mounted in the copiers for the U.S.A., Canada, and Europe.)

20. Refit the parts to the Imaging Unit and reinstall the Imaging Unit in the copier. 21. Charge fresh starter and make the ATDC adjustment. See p. D-49.

D-29

(2) Cleaning of the Main Erase Lamp

1. Remove four screws and PWB-A. 2. Remove three screws and HV1. 3. Unplug the connector of the Main Erase Lamp.

4. Remove the Imaging Unit. 5. Pull out the Toner Bottle Holder to the front. 6. Remove one screw and the Main Erase Lamp.

7. Using a brush or a soft cloth dampened with alcohol, clean the Erase Lamp. NOTE Do not touch the Lamp with bare hands.

(3) Cleaning of the Edge Erase Lamp

1. Remove four screws and PWB-A.

1151D034AA

2. Insert PWB-A into the copier to secure it.

1151D035AA

D-30

3. Go to the rear of the copier and unplug the connector of Edge Erase Lamp.

1151D036AA

4. Remove the Imaging Unit. 5. Remove one screw and the Edge Erase Lamp. NOTE When removing the Erase Lamp, use care not to lose the pressure spring in the rear.

6. Using a brush or a soft cloth dampened with alcohol, clean the Erase Lamp. NOTE After the Erase Lamp has been cleaned, make the Adjustment of the Edge Erase Lamp Position. See p. D-59.

D-31

2-7. PC DRUM CHARGE CORONA/IMAGE TRANSFER CORONA UNIT (1) Cleaning of the PC Drum Charge Corona Housing
1. Remove the Imaging Unit. 2. Remove one screw and PC Drum charge Corona Unit. 3. Press the Mesh Holder on the front of the Corona Unit in the direction of arrow A to remove the Grid Mesh.

1151D037AA

4. Remove the Cleaning Pad Cover. 5. Remove the End Caps from the front and rear ends of the Unit.

6. Remove the Comb Electrode. NOTE Use care not to deform the Electrode. When removing it, first snap off its spring end.

7. Using a soft cloth dampened with alcohol, wipe the Housing clean of dirt.

(2) Cleaning of the PC Drum Charge Corona Grid Mesh

1. Blow all foreign matter off the Grid with a blower brush. NOTE If the blower brush is not effective in cleaning the Grid, use a soft cloth dampened with alcohol to clean serious contamination.

D-32

(3) Cleaning of the Comb Electrode

1. Clean the Comb Electrode using the Corona Unit Cleaning Lever.

(4) Cleaning of the Image Transfer/Paper Separator Coronas Wires

1. Clean the Image Transfer Corona Wire using the Corona Wire Cleaning Lever.

2. Remove the four Paper Guides. 3. Dampen a soft cloth with alcohol, hold it with a pair of tweezers, and wipe the Paper Separator Corona Wire gently in one direction. (Go from the hook to spring end.)

(5) Cleaning of the Image Transfer/Paper Separator Coronas Housing

1. Remove the four Paper Guides. 2. Remove the two End Caps. 3. Remove the Image Transfer and Paper Separator Corona Wires. NOTE When removing the Wire, unhook the spring end first and use care to prevent break and deformation. (Use a pair of tweezers) Keep the Corona Wire Cleaning Lever (for the Image Transfer Corona) pressed all the way back in. Do not attempt to remove the Lower Pre-Image Transfer Guide Plate as it has been adjusted for correct height. 4. Using a soft cloth dampened with alcohol, wipe the Housing clean of dirt.

D-33

(6) Cleaning of the Lower Pre-Image Transfer Guide Plate

1. Using a brush, whisk dust off the Lower Pre-Image Transfer Guide Plate.

(7) Replacement of the Ozone Filter

1. Press the Filter Cover Bracket in the direction of the arrows and pull it off. 2. Remove the Filter and replace it with a new one.

1151D045AA

1158SBD0208A

2-8. Fusing Unit (1) Removal of the Fusing Unit

1. Remove one screw and the Ground Wire of the Fusing Unit.

1151D038AA

2. Unplug the Fusing Heater Lamp connector and remove the wires from the clamp.

1151D007AA

3. Unplug the Fusing Thermistor connector and remove the wires from the two clamps.

1151D008AA

D-34

4. Remove one screw and the Fusing Unit Locking Plate. 5. Turning it in the direction of the arrow, remove the Fusing Unit.

NOTE When reinstalling the Fusing Unit, install the Locking Plate as illustrated on the left.

(2) Cleaning of the Pre-Fusing Guide Plate

1. Using a soft cloth dampened with alcohol, wipe clean the Guide Plate.

(3) Removal of the Upper Fusing Roller

1. Remove two screws and the Fusing Unit Front Cover. 2. Remove two screws and the Fusing Unit Upper Cover.

3. Remove two screws and the Upper Paper Separator Fingers Unit.

D-35

4. Remove four Cord Holders of the Fusing Thermistor. 5. Remove one screw and the Fusing Thermistor.

1151D011AA

6. Remove the screw and clamp that secure the Lamp harness at the front of the copier.

1151D012AA

7. Remove the rear lamp harness and harness clamp (six). 8. Remove the mounting bracket (one screw).

1151D013AA

9. Remove the Fusing Thermoswitch (two screws).

1151D014AA

D-36

10. Slide out the Fusing Heater Lamp.

11. 12. 13. 14.

Remove two C-clips. Remove one spur gear. Remove two bushings. Remove the Upper Fusing Roller.

(4) Cleaning of the Upper Fusing Roller

1. Using a soft cloth dampened with alcohol or silicone oil, wipe clean the Upper Fusing Roller.

(5) Cleaning of the Upper Paper Separator Fingers

1. Using a soft cloth dampened with alcohol or silicone oil, wipe clean the Upper Separator Fingers.

(6) Cleaning of the Fusing Thermistor

1. Remove one screw to remove the Fusing Thermistor. 2. Using a soft cloth dampened with alcohol or silicone oil, wipe clean the Thermistor.

1151D039AA

D-37

(7) Removal of the Lower Fusing Roller

1. Turning it in the direction of the arrow, remove the Lower Separator Fingers Unit.

2. Remove the Lower Fusing Roller

(8) Cleaning of the Lower Fusing Roller

1. Using a soft cloth dampened with alcohol or silicone oil, wipe clean the Lower Fusing Roller.

(9) Cleaning of the Lower Paper Separator Fingers

1. Using a soft cloth dampened with alcohol or silicone oil, wipe clean the Lower Separator Fingers.

D-38

(10) Removal of the Oil Roller

1. Remove the front holder (one screw). 2. Remove the front bushing.

1151D015AA

(11) Cleaning of the Oil Roller

1. Using a brush, clean the Oil Roller.

D-39

ADJUSTMENT

3-1. JIGS AND TOOLS USED

z Important D When adjusting the positions of the Scanner and Mirrors Carriage, use Jigs numbered and . D When adjusting the gap between the Doctor Blade and Sleeve Roller, use Jigs numbered and . D When adjusting the position of PC Drum Paper Separator Fingers, use Jigs numbered and . Cable Holding jig Front Door Interlock Switch Actuating Jig

Scanner Positioning jig

Scanner/Mirrors Carriage Positioning jig

1151D022AA

Sleeve/Magnet Roller Position jig

D.B. Adjusting jigs

PC Drum Paper Separator Fingers Positioning jig

D-40

3-2. ADJUSTMENT REQUIREMENTS LIST

Adjustment Item Max. Exposure Lamp Voltage Optimum Exposure Setting in the Manual Exposure Mode Optimum Exposure Setting in the Auto Exposure Mode Multi Bypass Table Reference Position 1st Drawer Reference Position Full Size Leading Edge Registration Enlargement Leading Edge Registration Reduction Leading Edge Registration Image Leading Edge Erase Width Edge Erase Lamp Position (100 %) 20 2 mm (100 %) 20 2 mm (100 %) 20 1.5 mm (200 %) 40 3 mm (50 %) 10 1.5 mm 0.5 to 6.5 mm 1 0.5 mm Requirements 100 to 127V areas: 81 1 V 200 to 240V areas: 162 2 V Kodak Gray Scale: no image of the 1st step, faint image of the 2nd step Adjusting Point Control panel Ref. Page D-44

Control panel

D-47

Control panel Multi Bypass Table Drawer Front Panel Control panel Control panel Control panel Control panel Adjusting Screw for Edge Erase Lamp position

D-48 D-51 D-52 D-53 D-55 D-56 D-57 D-59

D-41

1151SBD0303A

3-3. ADJUSTMENT OF SWITCHES Microswitches

The following microswitches are used in various parts of this copier.

Blue Yellow

Red

Red

Wiring for the NO Type

Wiring for the NC Type

NC (Normally-Closed) : Current flows between NC and COM when the actuator is open. NO (Normally-Open) : Current flows between NO and COM when the actuator is closed. COM (Common) : Common contact for NC and NO Requirement Actuator The gap between the switch and actuator should be 0.1 mm to 0.5 mm when the actuator is closed.

COM 0.1 mm to 0.5 mm

NC NO

Out-of-Adjustment

(When the actuator is closed)

D If the gap between the switch and actuator is too big, current does not at times flow to NC or NO. D If there is no gap between the switch and actuator, the actuator is bent or the switch can be broken.

D-42

(1) Adjustment of Front Door Interlock Switch S21

1. Open the Right Door. 2. Remove the Middle Right Cover. (4 screws)

3. Remove the Upper Right Cover. (2 screws) 4. Remove the Right Cover. (2 screws)

5. Swing down the Front Door. 6. Remove the I/U Lock Lever. (1 screw) 7. Remove the Interlock Switch Cover. (2 screws)

8. Loosen the two screws that secure Front Door Interlock Switch S21. Move S21 as far toward the front side of the copier as it will go and temporarily secure it in position. 9. Gently swing the Front Door closed and then tighten the two S21 mounting screws to specification. D The Switch is wired for the NO type.

D-43

3-4. ELECTRICAL/IMAGE ADJUSTMENTS (1) Adjustment of the Maximum Exposure Lamp Voltage for the Manual Mode
z Requirement D Maximum Exposure Lamp voltage: 81 1V (RMS value) z Important D After the maximum Exposure Lamp voltage has been adjusted, be sure to make the following adjustments: Optimum Exposure Setting in the Manual Mode and Optimum Exposure Setting in the Auto Mode. 1. Remove the Large Cover. (3 screws) 2. Insert the probes of the multimeter into the receptacles of the Exposure Lamp voltage measurement connector.

3. On the control panel, press the Stop Key, Multi-Copy Key 0, Stop Key, and Multi-Copy Key 1, in that order, to set the copier into a state ready to enter a particular Tech. Rep. Mode. 4. Press Multi-Copy Key 1 and then 3 to set the copier into the F3 Test Mode. (At this time, the Magnification Ratio Indicator shows the currently set value and the Multi-Copy Display shown F3.)

5. Press the Full Size Key to select the Lamp voltage setting mode. (The Magnification Ratio Indicator shows L + current setting.) 6. Press the Start Key to light up the Exposure Lamp and, using the Zoom Up/Down Keys, adjust to obtain the Lamp voltage of 81V.

7. Press the Stop Key to stop the F3 operation. (Or, the operation will be automatically completed in about 30 sec.) 8. Press the Panel Reset Key twice (or turn OFF the Power Switch) to return the copier back into the normal mode. NOTE For the Root Mean Square values and Mean values, see p. 48-50. Most testers, voltmeters, or multimeters used in the field show only the mean values.

D-44

When using the testers, voltmeters, or multimeters which show only the mean value, not Rms values, carry out the following procedure. 1. 2. Measure the line voltage. Referring to the Mean Value Chart corresponding to each voltage area, see the figure under the voltage obtained in step 1.

If the line voltage is 125 V and Rms value is 81 V, for example, the mean value is 54.5 V. Therefore, it is recommended that the voltage be adjusted so that the mean value is set as close to 54.5 V as possible. MEAN VALUE CHART FOR 115/120/127V AREAS V Rms 81.0 104 60.7 105 60.3 106 60.0 107 59.7 108 59.2 109 59.0 110 58.5 111 58.2 112 58.0 113 57.7 MEAN VALUE

V Rms 81.0

114 57.3

115 57.0

116 56.8

117 56.5

118 56.2

119 56.0

120 55.7

121 55.5

122 55.2

123 55.0 MEAN VALUE

V Rms 81.0

124 54.7

125 54.5

126 54.3

127 54.2

128 54.0

129 53.7

130 53.5

131 53.2

132 53.0

133 52.8 MEAN VALUE

V Rms 81.0

134 52.7

135 52.5

136 52.2

137 52.1

138 52.0

139 51.7

140 51.5 MEAN VALUE

D-45

MEAN VALUE CHART FOR 200/220/240V AREAS V Rms 162.0 180 181 182 183 184 185 186 187 188 189 MEAN VALUE

135.9 135.2 134.5 133.8 133.2 132.6 131.9 131.4 130.8 130.2

V Rms 162.0

190

191

192

193

194

195

196

197

198

199 MEAN VALUE

129.7 129.1 128.6 128.1 127.6 127.1 126.6 126.1 125.7 125.2

V Rms 162.0

200

201

202

203

204

205

206

207

208

209 MEAN VALUE

124.7 124.2 123.9 123.5 123.1 122.7 122.2 121.9 121.5 121.1

V Rms 162.0

210

211

212

213

214

215 119.0

216

217

218 118.0

219 117.6 MEAN VALUE

120.7 120.4 120.0

119.7 119.2

118.6 118.2

V Rms 162.0

220 117.2

221 117.0

222 116.7

223

224

225 115.7

226

227

228 114.9

229 114.6 MEAN VALUE

116.4 116.1

115.5 115.2

V Rms 162.0

230 114.2

231 114.0

232 113.7

233

234

235 112.9

236

237

238 112.1

239 111.9 MEAN VALUE

113.5 113.2

112.7 112.4

V Rms 162.0

240 111.6

241 111.4

242 111.1

243

244

245 110.4

246

247

248

249 MEAN VALUE

110.9 110.6

110.2 109.9 109.7 109.5

V Rms 162.0

250

251

252

253

254

255

256

257

258

259 MEAN VALUE

109.2 109.0 108.7 108.6 108.2 108.1 107.9 107.7 107.5 107.2

V Rms 162.0

260

261

262

263

264

265

266

267

268

269 MEAN VALUE

107.1 106.9 106.6 106.4 106.2 106.0 105.7 105.6 105.4 105.2

V Rms 162.0

270

271

272

273

274 MEAN VALUE

105.1 104.9 104.7 104.5 104.2

D-46

(2) Adjustment of the Optimum Exposure Setting in the Manual Mode

z Requirement D When the manual exposure setting is at the central indication, no image of step no. 1 of a Kodak Gray Scale should be produced on the copy, but a faint image of step no. 2 should be produced.

No image of step no. 1 z Important

Faint image of step no. 2

1139D270AA

D This adjustment should be carried out only after completing Adjustment of the Maximum Exposure Lamp Voltage for the Manual Mode and Adjustment of the Aperture Blades. 1. Place the Kodak Gray Scale lengthwise, face down, and at the center on the Original Glass. Place a sheet of pure white A3 or 11 17 paper over it and then lower the Original Cover. 2. Set the copier into the Manual Exposure Mode. Set the Exposure Setting to the central or fifth indication and enter 15 copies to be made by using the Multi-Copy Keys. (Use A3 paper.) 3. Press the Start Key. Check that the 15th copy meets the requirement given above. 4. If the exposure is out of adjustment, press the Stop Key, Multi-Copy Key 0, Stop Key, and Multi-Copy Key 1, in that order, to set the copier into a state ready to enter a particular Tech. Rep. Mode. 5. Press Multi-Copy Key 1 and then 3 to set the copier into the F3 Test Mode. (At this time, the Magnification Ratio Indicator shows the currently set value and the Multi-Copy Display shows F3.)

6. Using the Zoom Up/Down Keys, vary the value on the Magnification Ratio Indicator as necessary. 7. After the adjustment has been made, press the Panel Reset Key twice (or turn OFF the Power Switch) to return the copier back into the normal mode. NOTE Increase the value to make the image lighter. Decrease the value to make the image darker.

D-47

(3) Adjustment of the Optimum Exposure Setting in the Auto Mode

z Important D This adjustment must be made after the optimum exposure setting in the Manual Mode has been adjusted. 1. Place about five sheets of A3 or 11 17 paper on the Original Glass and lower the Original Cover.

2. On the control panel, press the Stop Key, Multi-Copy Key 0, Stop Key, and Multi-Copy Key 1, in that order, to set the copier into a state ready to enter a particular Tech. Rep. Mode. 3. Press Multi-Copy Keys 1 and 5 to set the copier into the F5 Test Mode. (At this time, the Multi-Copy Display shows F5.)

4. Press the Start Key to let the copier make the adjustment. 5. After the adjustment has been made, press the Panel Reset Key twice (or turn OFF the Power Switch) to return the copier back into the normal mode.

NOTE Pressing the Start Key lets the copier make the adjustment of optimum exposure setting. During the adjustment, the Start Key is lit up orange. It turns to green as soon as the adjustment is completed. (It takes about 5 sec. to make the adjustment.) The Full Size Key can be used to alternately display on the Magnification Ratio Indicator either the adjusting value (AE Sensor memory level) or the voltage value (AE Sensor output).

D-48

(4) Adjustment of the ATDC Sensor

z Important D This adjustment is not necessary when a new Imaging Unit has been installed. (The ATDC Sensor is automatically adjusted when the starter is charged and the Power Switch turn ON.) D The adjustment must be made whenever the currently used Imaging Unit has been charged with new starter. 1. Load the starter.

2. On the control panel, press the Stop Key, Multi-Copy Key 0, Stop Key, and Multi-Copy Key 1, in that order, to set the copier into a state ready to enter a particular Tech. Rep. Mode. 3. Press Multi-Copy Keys 1 and 8 to set the copier into the F8 Test Mode. (At this time, the Multi-Copy Display shows F8.)

4. Press the Start Key to let the copier make the ATDC Sensor adjustment automatically. (It takes about 5 min. for the copier to complete the adjustment procedure.) 5. After the adjustment has been made, press the Panel Reset Key twice (or turn OFF the Power Switch) to return the copier back into the normal mode.

NOTE The I/U Counter available from the Consumables counter menu is automatically reset when the ATDC Sensor gain adjustment has been completed. The Full Size key can be used to alternately display the data on the Magnification Ratio Indicator, either the ATDC Sensor output voltage or ATDC Sensor gain.

D-49

(5) Adjustment of the Aperture Blades

z Requirement D There should be no dark or light bands running in the feeding direction on copies produced. (Adjust to obtain the mean image density for all areas.) z Important D If dark and light bands running in the feeding direction occur on copies, make this adjustment after checking the following. 1) The Drum Charge Corona Wire, Grid Mesh, and Image Transfer Corona Wire are free of dirt. 2) The surfaces of the Mirrors and Lens are free of dirt. 3) The surfaces of the Exposure Lamp and Main Erase Lamp are free of scratches and dirt. 4) The Cleaning Blade is free of waviness. 1. Make a copy under the following control panel settings. Original : A3 or A4 crosswise, 11 17 or 11 8-1/2 crosswise Paper : A3 or A4 crosswise, 11 17 or 11 8-1/2 crosswise Magnification : 100 % ratio Exposure : Manual (setting convenient for check)

2. Remove the Original Glass. 3. Turn the copy on the Copy Tray around as shown to reverse the leading and trailing edges and align it with the Aperture Blades.

4. Adjust to obtain the mean image density for all areas of the copy. NOTE To make the image darker, move the Aperture Blade toward the Auxiliary Reflector. To make the image lighter, move the Aperture Blade away from the Auxiliary Reflector.

D-50

(6) Adjustment of the Multi Bypass Table Reference Position

z Requirement D Ready a test chart (A3 or 11 17) as shown on the left. Draw a line on the chart at a point 20 mm from the right edge as shown. D Dimension A on the copy should measure 20 2.0 mm.

1. Place the test chart face down on the Original Glass and align its rear left corner with the marker on the Original Width Scale on the left side of the platen. Then, lower the Original Cover. 2. Using the Multi Bypass Table, make two full size copies. 3. Using the second copy, compare the position of the reference line on the copy with that on the test chart.

4. If the line does not meet the requirement, loosen the two screws (OPTION : three screws) that secure the Multi Bypass Table and move the Table as necessary in the direction of the arrows. NOTE If dimension A on the copy is smaller than 18 mm, move the Table to the front. If it is more than 22 mm, move the Table to the rear. When an Automatic or Duplexing Document Feeder is mounted, it involves changing the Original Glass. This in turn results in the position of the Original Length Scale being slightly shifted toward the rear. This is corrected by installing the Original Positioning Plate.

<OPTION>

1151D024AA

D-51

(7) Adjustment of the 1st Drawer Reference Position

z Requirement D Ready a test chart (A3 or 11 17) as shown on the left. Draw a line on the chart at a point 20 mm from the right edge as shown. D Dimension A on the copy should measure 20 2.0 mm.

z Important D If the Paper Tray of the Drawer needs to be moved for adjustment, make sure that it is moved straight, not slantwise (as skewed feeding of paper could result). 1. Place the test chart face down on the Original Glass and align its rear left corner with the marker on the Original Width Scale on the left side of the platen. Then, lower the Original Cover. 2. Using the 1st Drawer, make two full size copies. (Use A3 or 11  17 paper.) 3. Using the second copy, compare the position of the reference line on the copy with that on the test chart.

4. If the line does not meet the requirement, slide out the 1st Drawer, loosen the four screws shown on the left, and move the Paper Tray as necessary to the front or rear. NOTE If dimension A on the copy is smaller than 18 mm, move the Paper Tray to the rear. If it is more than 22 mm, move the Paper Tray to the front.

D-52

(8) Adjustment of the Leading Edge Registration Full Size

z Requirement D Ready a test chart (A3 or 11 17) as shown on the left. Draw a line across the test chart at a point 20 mm from the leading edge and use it as the reference line. Dimension A at the center on the copy should meet the following requirements. Mag. Ratio Full Size (100 %) Enlargement (200 %) Reduction (50 %) D Setting value range: 30 to 70 D Movement equivalent to 1 step of setting value: 0.28 mm z Important D After having set the copier into the Adjust Mode, make two single copies and use the second copy for the check. (The first copy represents the data before adjustment.) D When full size leading edge registration has been adjusted, it affects leading edge registration in the enlargement and reduction mode. Be sure, therefore, to check for registration in these modes, too. 1. Place the test chart face down on the Original Glass and align its rear left corner with the marker on the Original Width Scale on the left side of the platen. Then, lower the Original Cover. 2. Make two single copies in full size mode (100 %) and check for leading edge registration on the second copy. (If it meets the requirement, go to Adjustment of Enlargement Leading Edge Registration.) n Dimension A (mm) 20.0 1.5 40.0 3 10.0 1.5

D-53

3. If the registration does not meet the requirement, go to the control panel and press the Stop Key, Multi-Copy Key 0, Stop Key, and Multi-Copy Key 1, in that order, to set the copier into a state ready to enter a particular Tech. Rep. Mode. 4. Press the Stop Key and then press the Start Key to set the copier into the Adjust Mode. (At this time, the Magnification Ratio Indicator shows A.)

5. Press Multi-Copy Key 4 and press the Start Key. (Then, the Magnification Ratio Indicator shows A4 and the MultiCopy Display, the current setting value.)

6. Press the Clear Key to clear the current setting value. 7. With the old setting value used as reference, enter the new setting value using the appropriate Multi-Copy Keys. NOTE If dimension A on the copy is smaller than 18.5 mm, decrease the setting value. If dimension A on the copy is greater than 21.5 mm, increase the setting value.

8. Press the Start Key to validate the setting. 9. Press the Panel Reset Key twice (or turn OFF the Power Switch) to return the copier back to the normal mode. 10. Make two single copies and check for leading edge registration on the second copy. (If it does not meet the requirement, perform steps 3 through 10 again.)

D-54

Enlargement
1. After the leading edge registration in the full size mode has been adjusted, make two single copies in an enlargement mode (200 %) and check for leading edge registration on the second copy. (If the enlargement leading edge registration meets the requirement, go to Adjustment of Reduction Leading Edge Registration.)

2. If the registration does not meet the requirement, go to the control panel and press the Stop Key, Multi-Copy Key 0, Stop Key, and Multi-Copy Key 1, in that order, to set the copier into a state ready to enter a particular Tech. Rep. Mode. 3. Press the Stop Key and then press the Start Key to set the copier into the Adjust Mode. (At this time, the Magnification Ratio Indicator shows A.)

4. Press Multi-Copy Key 5 and press the Start Key. (Then, the Magnification Ratio Indicator shows A 5 and the Multi-Copy Display, the current setting value.)

5. Press the Clear Key to clear the current setting value. 6. With the old setting value used as reference, enter the new setting value using the appropriate Multi-Copy Keys. NOTE If dimension A on the copy is smaller than 8.5 mm, decrease the setting value. If dimension A on the copy is greater than 11.5 mm, increase the setting value.

7. Press the Start Key to validate the new setting. 8. Press the Panel Reset Key twice (or turn OFF the Power Switch) to return the copier back to the normal mode. 9. Make two single copies and check for leading edge registration on the second copy. (If it does not meet the requirement, perform steps 2 through 9 again.)

D-55

Reduction
1. After the leading edge registration in an enlargement mode has been adjusted, make two single copies in a reduction mode (50 %) and check for leading edge registration on the second copy.

2. If the registration does not meet the requirement, go to the control panel and press the Stop Key, Multi-Copy Key 0. Stop Key, and Multi-Copy Key 1, in that order, to set the copier into a state ready to enter a particular Tech. Rep. Mode. 3. Press the Stop Key and then press the Start Key to set the copier into the Adjust Mode. (At this time, the Magnification Ration Indicator shows A.)

4. Press Multi-Copy Key 5 and press the Start Key. (Then, the Magnification Ratio Indicator shows A5 and the MultiCopy Display, the current setting value.)

5. Press the Clear Key to clear the current setting value. 6. With the old setting value used as reference, enter the new setting value using the appropriate Multi-Copy Keys. NOTE If dimension A on the copy is smaller than 8.5 mm, decrease the setting value. If dimension A on the copy is greater than 11.5 mm, increase the setting value.

7. Press the Start Key to validate the new setting. 8. Press the Panel Reset Key twice (or turn OFF the Power Switch) to return the copier back to the normal mode. 9. Make two single copies and check for leading edge registration on the second copy. (If it does not meet the requirement, perform step 2 through 9 again.)

D-56

(9) Adjustment of the Image Leading Edge Erase Width

z Requirement D Ready a test chart (A3 or 11 17) as shown on the left. Paint a 20 mm-long rectangle in black at the center of the test chart along its leading edge as shown. Adjust so that the erase width along the leading edge of the painted area measures 0.5 to 6.5 mm.

D Setting value range: 42 to 58 D Movement equivalent to 1 step of setting value: 0.75 mm D Having a greater setting value results in a greater erase width. D Having a smaller setting value results in a smaller erase width. z Important D This adjustment must be made after the leading edge registration adjustment has been completed. 1. Place the test chart face down on the Original Glass and align its rear left corner with the marker on the Original Width Scale on the left side of the platen. Then, lower the Original Cover. 2. Make two single copies in full size mode (100 %) and check for leading edge erase width on the second copy.

3. If the erase width does not meet the requirement, go to the control panel and press the Stop Key, Multi-Copy Key 0, Stop Key, and Multi-Copy Key 1, in that order, to set the copier into a state ready to enter a particular Tech. Rep. Mode. 4. Press the Stop Key and then press the Start Key to set the copier into the Adjust Mode. (At this time, the Magnification Ratio Indicator shows A.)

5. Press Multi-Copy Key 1 S 2 and press the Start Key. (Then, the Magnification Ratio Indicator shows A 12 and the Multi-Copy Display, the current setting value.)

D-57

6. Press the Clear Key to clear the current setting value. 7. With the old setting value used as reference, enter the new setting value using the appropriate Multi-Copy Keys. NOTE If the erase width on the copy is less than 0.5 mm, increase the setting value. If the erase width on the copy exceeds 6.5 mm, decrease the setting value.

8. Press the Start Key to validate the setting. 9. Press the Panel Reset Key twice (or turn OFF the Power Switch) to return the copier back to the normal mode. 10. Make two single copies and check for leading edge erase width on the second copy. (If it does not meet the requirement, perform steps 3 through 9 again.)

D-58

(10) Adjustment of the Edge Erase Lamp Position

z Requirement D Edge erase width: Within 1 0.5 mm z Important D This adjustment must be made after the reference positions of the Multi Bypass Table and 1st Drawers have been adjusted. 1. With the Original Cover raised, place a sheet of A4 or 8-1/2 11 paper lengthwise on the Original Glass.

2. With the Original Cover raised, make a full size copy. 3. Check the erase width on the front edge and turn the edge erase width adjusting screw as necessary to obtain an erase width of less than 1 0.5 mm.

NOTE Loosening the screw will make the erase width smaller. Tightening the screw will make the erase width greater.

D-59

3-5. OTHER ADJUSTMENTS (1) Adjustment of the Scanner/Mirrors Carriage Position

z Requirement D With the Scanner positioned correctly with reference to the upper copier frame, there should be no gap between the Scanner/Mirrors Carriage and the Scanner/Mirrors Carriage Positioning Jig. 1. Remove the Original Cover, Original Scales, and Original Glass. 2. Temporarily tighten the screw on the Scanner Drive Cable Holding Bracket.

3. Align the rectangular hole in the upper copier frame with the U-groove in the Scanner, then insert the Scanner Positioning Jig into the hole.

4. Install the Scanner/Mirrors Carriage Positioning Jig between the Scanner and Mirrors Carriage.

5. Loosen the screw that has been temporarily tightened in step 2. Turn the helical gear of the Scan Pulley to press the Mirrors Carriage up against the Scanner/Mirrors Carriage Positioning Jig and the Scanner. 6. Tighten the screw on the Scanner Drive Cable Holding Bracket.

1151D055AA

D-60

(2) Adjustment of the Gap Between the Doctor Blade and Sleeve Roller
z Requirement D The gap between the Doctor Blade and the Sleeve Roller should be 0.35 mm 0.05 mm. z Important D Cover the PC Drum with the Drum Cloth to prevent it from being scratched. 1. Remove the Developer Scattering Prevention Plate. 2. Wipe the developer off the surface of the Sleeve Roller.

3. Install the Sleeve/Magnet Roller Positioning Jig onto the Imaging Unit.

4. Loosen the three screws securing the Doctor Blade in position. Insert the D.B. Adjusting Jigs into the space between the Doctor Blade and Sleeve Roller. 5. Press down the Doctor Blade until it positively contacts the D.B. Adjusting Jigs, then tighten the three screws to secure it in position.

D-61

(3) Adjustment of the PC Drum Paper Separator Fingers Position

z Requirement D The gap between the PC Drum and the PC Drum Paper Separator Fingers should be 1.0 0.5 mm when the Separator Solenoid is in the deenergized position. z Important D Cover the PC Drum with the Drum Cloth to prevent it from being scratched. D Use care not to deform the Separator Fingers during the adjustment procedure. D Press part A shown below up against the PC Drum Paper Separator Fingers Positioning Jig for the adjustment (to prevent the Paper Separator Fingers from being deformed). 1. Install the Sleeve/Magnet Roller Positioning Jig, to which the PC Drum Paper Separator Fingers Positioning Jig has been fitted, onto the Imaging Unit.

2. Turn the set screw on each of the two Finger Holders as necessary for the adjustment.

3. Ensure that part A contacts the PC Drum Paper Separator Fingers Positioning Jig when the Separator Solenoid is in the deenergized position.

D-62

MISCELLANEOUS

4-1. INSTALLATION OF THE PLUG-IN COUNTER MOUNTING BRACKET (OPTION)

1. Remove the Middle Right Cover.

2. Remove the Counter Cover. 3. Remove the Upper Right Cover. 4. Remove the Right Cover.

5. Connect the Plug-In Counter Connector.

6. Secure the Plug-In Counter Mounting Bracket by tightening the two screws.

D-63

TROUBLESHOOTING

1158SBT000BA

CONTENTS
*:Only when options are used 1 INTRODUCTION 1-1. General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T-1 1-2. How to Use This Book . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T-1 1-3. Reading the Text . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T-1 2 I/O PORT CHECK 2-1. Method for Checking the Control Parts with Loads . . . . . . . . . . . . . . T-2 2-2. I/O Port Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T-4 3 PAPER TRANSPORT FAILURE 1. Paper Misfeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T-7 1-1. Misfeed Detected When Copier is Turned ON . . . . . . . . . . . . . . . T-10 1-2. Copier Take-Up Misfeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T-11 1-3. Bypass Port Misfeed (*Multi Bypass Table) . . . . . . . . . . . . . . . . . T-14 1-4. Transport/Separator Misfeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T-16 1-5. Fusing/Exit Misfeed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T-19 2. Wrinkles in Paper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T-21 3. Double Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T-21 4. Skewed Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T-22 4 MALFUNCTIONS 1. Self-Diagnostic Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. C0000: Main Drive Motors failure to turn . . . . . . . . . . . . . . . . . . . C0001: Main Drive Motor turning at abnormal timing 1-2. C0010: PC Drive Motors failure to turn . . . . . . . . . . . . . . . . . . . . C0011: PC Drive Motor turning at abnormal timing 1-3. C004C: Cooling Fan Motors failure to turn . . . . . . . . . . . . . . . . . 1-4. C0070: Toner Replenishing Motors failure to turn . . . . . . . . . . . C0071: Toner Replenishing Motor turning at abnormal timing 1-5. C0400: Exposure Lamps failure to turn ON . . . . . . . . . . . . . . . . C0410: Exposure Lamp turning ON at abnormal timing 1-6. C0500: Warming-up failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C0510: Abnormally low fusing temperature C0520: Abnormally high fusing temperature 1-7. C0600: Scanner Motor malfunction . . . . . . . . . . . . . . . . . . . . . . . C0610: Lens Motor malfunction C0620: Mirror Motor malfunction T-23 T-25 T-27 T-29 T-31

T-33 T-35

T-37

1-8. C0F10: Faulty AE Sensor level . . . . . . . . . . . . . . . . . . . . . . . . . . . C0F30: ATDC Sensor malfunction 1-9. C0F02: Original size detection error (Defective CPU) . . . . . . . . C0FE1 To C0FFF: Original Size Detecting Sensor failure 2. Power is not Turned ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3. E1, E2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

T-39 T-41 T-43 T-45

ii

1139SBT0100A

INTRODUCTION

1139SBT0101A

1-1. General Precautions

1. When servicing the copier with its covers removed, use utmost care to prevent your hands, clothing, and tools from being caught in revolving parts including the chains and gears. 2. Before attempting to replace parts and unplug connectors, make sure that the power cord of the copier has been unplugged from the wall outlet. 3. Never create a closed circuit across connector pins except those specified in the text and on the printed circuit. 4. When creating a closed circuit and measuring a voltage across connector pins specified in the text, be sure to use the green wire (GND). 5. When the user is using a word processor or personal computer from a wall outlet of the same line, take necessary steps to prevent the circuit breaker from opening due to overloads. 6. Keep all disassembled parts in good order and keep tools under control so that none will be lost or damaged.
1139SBT0102A

1-2. How to Use This Book

1. If a component on a PWB or any other functional unit including a motor is defective, the text only instructs you to replace the whole PWB or functional unit and does not give troubleshooting procedure applicable within the defective unit. 2. All troubleshooting procedures contained herein assume that there are no breaks in the harnesses and cords and all connectors are plugged into the right positions. 3. For the removal procedures of covers and parts, see DIS/REASSEMBLY, ADJUSTMENT. 4. The troubleshooting procedures are given in the order of greater frequency of trouble or order of operation. 5. The procedures preclude possible malfunctions due to noise and other external causes.
1139SBT0103A

1-3. Reading the Text

1. The paper transport failure troubleshooting procedures are given according to the symptom. First identify the location where the paper is present and start the procedure for that particular location. For malfunction troubleshooting, start with step 1 and onward. 2. Make checks in numerical order of steps and, if an item is checked okay, go to the next step. Pattern 1 Step Check Item 1 2 Is--? Result Action Pattern 2 Step Check Item 1 Is--? Result YES NO Action Do this.

YES Do this. Go to step 2 if it checks okay.

Check that. Go to step 2 if it checks okay.

T-1

1151SBT0200A

2 I/O PORT CHECK

1158SBT0201A

2-1. Controlled Parts Check Procedure

To allow the Tech. Rep. to easily and safely determine whether a particular controlled part is fully operational, this copier provides the following provision: the check of the data of the I/O port on the board IC with the copier in the standby state (including a misfeed, malfunction, and closure failure condition) allows the Tech. Rep. to determine whether a signal is properly input to, and output from, a controlled part.

<Procedure> 1) When a paper misfeed or malfunction occurs, identify the I/O port of the possibly defective controlled part by reviewing the text or I/O port check list. 2) Select the I/O Check function of the Service mode and show on the Touch Panel the status of the I/O port identified in step 1. 3) Check the input or output port data to determine whether the controlled part is operational and signals are properly input and output.

T-2

<Controlled Part Check Procedure by Changing Input Port Data>

Example: When a paper misfeed occurs in the paper take-up section of the copier, Paper Take-Up Sensor PC55 is considered to be responsible for it. <Procedure> 1) Remove the sheet of paper misfed. 2) From the I/O port check list, it is found that the H/L input signal to PC55 is supplied from PWB-A (IC4A) APA1. 3) Select the I/O Check function from the Service mode menu and, using the Paper Select key, show the status of PWB-A (IC4A) APA1 on the control panel. 4) Check that the second LED from the right of the Exposure Information Display lights up (sensor being unblocked). Zoom Ratio Indicator Multi-Copy Display Exposure Information Display 7 6 5 4 3 2 1 0 5) Move the PC55 actuator to block the sensor. 6) Check at this time that the LED goes out. ON: PC55 is faulty. OFF: PC55 is operational.

XAPA 4A

T-3

1158SBT0202A

: 1st Drawer paper take-up LED on the Monitor Display lights up. Multi-Copy Display ON OFF 1A 4A 5A 4A 4A 4A OFF Indicator OFF ON Manual Exposure

2-2. Port Check List (Copier)

Port No. Ratio Indicator P47 P67 P43 P66 P43 P43 P61 P62 P61 P62 P61 P62 BPA5 OUTO APC2 BPA6 BPA4 BPA BPA APC OUT BPA P6 P4 P4 P6 P4 P6 P4 Magnification

Symbol

Name

Operation Characteristics CN/PJ No.

M1

PC Drive Motor

PJ12A-8

M1

PC Drive Motor lock signal

When locked When turned PJ12A-7 ON PJ12A-10

M2

Main Drive Motor

M2

Main Drive Motor lock signal

When locked When turned PJ12A-9 OFF OFF OFF ON OFF OFF ON OFF OFF OFF ON ON ON PJ16A-3 OFF ON PJ16A-1 ON OFF PJ16A-2 ON ON ON PJ5A-5 PJ6A-9 When locked When turned PJ6A-11 OFF OFF ON ON PJ14A-2 PJ7A-9 PJ32A-2 PJ6A-8

M3

Optical Section Cooling Fan Motor

M4

Suction Fan Motor

T-4

M5

Scanner Motor

M6

Lena Motor

M7

Mirror Motor

M8

Toner Replenishing Motor

M9

Cooling Fan Motor

M9

Cooling Fan Motor lock signal

SL1

Separator Solenoid

SL2

Paper Take-Up Solenoid

Symbol Ratio Indicator ON OFF ON OFF PB0 PB 4A Display Indicator

Name

Port No.

Magnification

Multi-Copy

Manual Exposure

Operation Characteristics CN/PJ No.

SL51

Manual Feed Paper Take-Up Solenoid (down) PB1 OFF ON

PJ12A-8

SL51

Manual Feed Paper Take-Up Solenoid (up) BPA0 BPA1 PB2 PB APC 5A APC3 BPA 4A OFF OFF OFF When unblocked When unblocked When unblocked When unblocked When unblocked 4A When unblocked

PJ12A-10

CL1

Synchronizing Roller Clutch

ON ON

PJ6A-8 PJ16A-3 OFF When blocked When blocked When blocked When blocked When blocked When blocked PJ18A-6

CL2

Paper Transport Clutch

CL51

Manual Feed Paper Take-Up Clutch

PC31

Manual Feed Paper Empty Sensor

T-5
APC7 APC5 APC6 APA1 APA APA0 APA

PC51

Transport Roller Sensor

PC53

Paper Exit Sensor

PJ21A-2

PC54

Paper Leading Edge Detecting Sensor

PJ11A-6

PC55

Paper Take-Up Sensor

PJ7A-2

PC57

Right Door Detecting Sensor

PJ16A-3

Symbol Ratio Indicator ON When unblocked When unblocked When unblocked When unblocked When unblocked When blocked When blocked When blocked When blocked When blocked OFF APB0 APB 4A Display Indicator

Name

Port No.

Magnification

Multi-Copy

Manual Exposure

Operation Characteristics CN/PJ No.

PC81

Scanner Reference Position Sensor

PJ22A-1

PC86

Mirror Reference Position sensor APB2

PJ20A-2

PC90

lena Reference Position Sensor APB1 APB 4A

PJ20A-5

PC101

Paper Empty Sensor APA2 APA

PJ7A-6

PC112

Toner Hopper Home Position Sensor APB6 APB 4A

T-6

PJ22A-10

1151SBT0300A

3 PAPER TRANSPORT FAILURE

1158SBT0301A

1. Paper Misfeed
When a paper misfeed occurs in the copier, the corresponding Misfeed Location Monitor LED on the control panel blinks to let the user know where the misfeed has occurred. If an LED lights up steadily, it indicates that there might be a sheet of paper present at that particular location in the copier. If a paper misfeed occurs very frequently, carry out the necessary troubleshooting procedures according to the location of the misfeed.

Blinking Light

There is a misfeed at that location. There might be a sheet of paper stopped at that location.

Steady Light

Blinking LED F

Misfeed Location Paper take-up/Bypass port/Vertical transport/Transport/Separator/Fusing/Exit

T-7

The paper misfeed, is detected by the following sensors.

*:When option is installed (Exit/Duplex Switching Unit) Paper Leading Edge Detecting Sensor PC54 Transport Roller Sensor PC51 Paper Take-Up Sensor PC55

Paper Exit Sensor PC53

T-8

D Here is an at-a-glance listing of misfeed detections made by the various sensors of the copier. A: Misfeed Detected in Conjunction with Leading Edge Detection Blinking LED Location Before the Paper Take-Up Sensor Before the Transport Roller Description Take-up failure Timer Start Paper take-up start Sensor Timing Paper Take-Up Sensor (leading edge) Transport Roller Sensor (leading edge) Paper Leading Edge Detecting Sensor (leading edge) Paper Exit Sensor (leading edge)

Leading edge detection by the Transport Roller Sensor Leading edge detection by the Paper Leading Edge Detecting Sensor Leading edge detection by the Paper Exit Sensor

Leading edge detection by the Paper Take-Up Sensor Leading edge detection by the Transport Roller Sensor TRON signal

Before the Paper Leading Edge Detecting Sensor

From Image Transfer Corona to Fusing Unit

B: Misfeed Detected in Conjunction with Trailing Edge Detection Blinking LED Location Vertical Transport Section Description Trailing edge detection by the Paper Take-Up Sensor Trailing edge detection by the Transport Roller Sensor Trailing edge detection by the Paper Leading Edge Detecting Sensor Trailing edge detection by the Paper Exit Sensor Timer Start Leading edge detection by the Paper Take-Up Sensor TRON signal Sensor Timing Paper Take-Up Sensor (trailing edge) Transport Roller Sensor (trailing edge) Paper Leading Edge Detecting Sensor (trailing edge) Paper Exit Sensor (trailing edge)

Near the Transport Roller Sensor

Near the Paper Leading Edge Detecting Sensor

Trailing edge detection by the Transport Roller Sensor Trailing edge detection by the Paper Leading Edge Detecting Sensor

From the Suction to Fusing Unit

T-9

1158SBT030101A

1-1. Misfeed Detected When Copier is Turned ON

Procedure 1. Check for lit LED and remove a sheet of paper if present at the LED location 2. If an LED or LEDs light up again, perform the following procedure.

Lit LED

Paper Location Drawer

Sensor Paper Take-Up Sensor PC55

Action See step 10 on p. T-13 (Copier Take-Up Misfeed Clearing Procedure). See step 14 on p. T-13 (Copier Take-Up Misfeed Clearing Procedure). See step 2 on p. T-17 (Transport/Separator Misfeed Clearing Procedure). See step 8 on p. T-20 (Fusing/Exit Misfeed Clearing Procedure).

Transport Roller F

Transport Roller Sensor PC51

Synchronizing Roller

Paper Leading Edge Detecting Sensor PC54 Paper Exit Sensor PC53

Exit Section

T-10

1158SBT030102A

1-2. Copier Take-Up Misfeed

Symbol PC51 PC55 SL2 CL2 PWB-A Name Transport Roller Sensor Paper Take-Up Sensor Paper Take-Up Solenoid Paper Transport Clutch Main Control Board

1158C01TAA

T-11

z Copier Take-Up Misfeed Clearing Procedure Symptom D Paper is not taken up at all. D Paper is stationary before the Paper Take-Up Sensor. Step 1 Check Item Is the paper being used up to product specifications? Is the paper curled, waved, or damp? Are the Separator Fingers on both sides of the Drawer in position? Are the Separator Fingers deformed? Is the Trailing Edge Stop or Edge Guide in good position? Are the Paper Lifting Springs positioned correctly? Are the Paper Take-Up Rolls deformed, worn, or dirty with paper dust? Is a signal being output from PWB-A to the Paper Take-Up Solenoid? 8 * Does the voltage across PJ7A-9 on PWB-A and GND change from DC24V to DC0V when the Start Key is pressed? Is the Clutch Spring deformed or worn? Result NO Action Instruct the user to use the paper that is up to product specifications. Change the paper. Instruct the user in how to store the paper. Instruct the user to load the paper so that it rests under the Fingers. Replace the Fingers. Instruct the user in how to position the Edge Stop or Guide. Change the position of the Spring or add one as necessary. Clean or replace the Paper Take-Up Rolls. Adjust the Solenoid stroke. Check the Solenoid.

YES

3 4 5

NO YES NO

NO

YES

YES

Replace PWB-A. NO Replace the Clutch Spring.

9 Continued on next page

YES

T-12

Symptom D Paper is stationary before the Vertical Transport Roller. D Paper is stationary at the Vertical Transport Roller.

Step

Check Item Check Paper Take-Up Sensor (PC55). Seep.T-3. PC55: PWB-A (IC4A) APA1

Result YES

Action Replace PWB-A. Check the Actuator for operation. Check the Paper Take-Up Sensor. Clean or replace the Vertical Transport Rollers. Clean, correct, or replace the Guide Plate.

10

NO

11

Are the Vertical Transport Rollers deformed, worn, or dirty with paper dust? Are the Paper Take-Up Guide Plate and Vertical Transport Guide Plate dirty or deformed? Is a signal being output from PWB-A to the Clutch? * Does the voltage across PJ6A-2 on PWB-A and GND change from DC24V to DC0V when the Start Key is pressed? Check Transport Roller Sensor PC51 See p. T-3 (PWB-A (IC4A) APC7).

YES

12

YES

Check the Clutch. YES

13

Replace PWB-A. NO

D Paper is stationary near the Transport Roller.

YES

Replace or check the PWB-A. Check the Actuator for operation. Check PC51. Clean or replace the Transport Rollers.

14

NO Are the Transport Rollers deformed, worn, or dirty with paper dust?

15

YES

T-13

1158SBT030103A

1-3. Bypass Port Misfeed

Symbol PC51 SL51 CL2 CL51 PWB-A Name Transport Roller Sensor Manual Feed Paper Take-Up Solenoid Paper Transport Clutch Manual Feed Paper Take-Up Clutch Main Control Board

1151C02TAA

T-14

z Bypass Port Misfeed Clearing Procedure Symptom Step 1 Check Item Does the misfeed occur when the Manual Bypass Table is used? Is paper taken up and fed in properly from the Drawer? 2 NO Result YES Action Perform the troubleshooting procedure for Transport/Separator Misfeed. Perform the troubleshooting procedure for Copier Take-Up and Transport/Separator Misfeed. Instruct the user to use the paper that is up to product specifications. Change the paper. Instruct the user in how to store the paper. Adjust the stroke of the Solenoid. Check the Solenoid.

D Paper is not taken up at all.

Is the paper being used up to product specifications? Is the paper curled, waved, or damp? Are the Paper Take-Up Rolls pressed against the paper stack when the Start Key is pressed?

NO

YES

YES

* Does the voltage across PJ11A-2 on PWB-A and GND change from DC24V to DC0V when the Start Key is pressed? Does the voltage across PJ7A-5 on PWB-A and GND change from DC24V to DC0V when the Start Key is pressed? Is the Pressure Pad or Guide Plate deformed or dirty? Are the Paper Take-Up Rolls deformed, worn, or dirty with paper dust? Check Transport Roller Sensor PC51 Seep. T-3 (PWB-A (IC4A) APC7). Does the voltage across PJ6A-6 on PWB-A and GND change from DC24V to DC0V when the Start Key is pressed? Is the Transport Roller or Guide Plate of the copier deformed, worn, or dirty with paper dust?

Replace PWB-A. NO

YES

Check the Clutch.

NO

Replace PWB-A.

YES

Clean or replace the Pressure Pad or Guide Plate. Clean or replace the Paper Take-Up Rolls. Check the Actuator for operation. Check PC51. Check the Clutch.

8 D Paper is stationary near the Transport Roller.

YES

NO

YES

10

NO

Replace PWB-A.

11

YES

Clean or replace the Vertical Transport Roller or Guide Plate.

T-15

1158SBT030104A

1-4. Transport/Separator Misfeed

Symbol PC51 PC54 SL1 CL1 M3 PWB-A Name Transport Roller Sensor Paper Leading Edge Detecting Sensor Separator Solenoid Synchronizing Roller Clutch Suction Fan Motor Main Control Board

1151C24TAA

T-16

z Transport/Separator Misfeed Clearing Procedure Symptom D Paper is stationary before the Synchronizing Roller. Step 1 Check Item Is the paper curled, waved, or damp? Check Paper Leading Edge Detecting Sensor PC54 See p. T-3 (PWB-A (IC4A) APC6). Do the Synchronizing Rollers turn? 3 * Does the voltage across PJ6A-4 on PWB-A and GND change from DC24V to DC0V after the Start Key has been pressed? Is a given length of loop formed before the Synchronizing Roller? Is the Pre-Image Transfer Guide Plate deformed or dirty? Is the Corona Unit Cleaning Lever (Lower) in correct position? Are the Image Transfer/Paper Separator Corona Wires deteriorated or dirty? Are the Paper Guides deformed or dirty? Are the Synchronizing Rollers deformed, worn, or dirty with paper dust? Result YES YES NO Action Change the paper. Instruct the user in how to store the paper. Replace PWB-A. Check the Actuator for operation. Check PC54. Check the Clutch. YES

Replace PWB-A. NO

4 D Paper is stationary near the PC Drum.

NO

Adjust the loop length or clean or replace the Transport Rollers. Correct or clean the Guide Plate. Place the Lever in position.

YES

NO Clean or replace the Wires. YES

YES

Clean or replace the Paper Guides. Clean or replace the Synchronizing Rollers.

YES

T-17

Symptom D Paper is wedged at the Paper Separator Fingers.

Step

Check Item Does the voltage across PJ14A-2 on PWB-A and GND change from DC24V to DC0V after the Start Key has been pressed? Are the Paper Separator Fingers deformed or dirty? Check Transport Roller Sensor PC51 See p. T-3 (PWB-A (IC4A) APC7). Check Paper Leading Edge Detecting Sensor PC54 See p. T-3 (PWB-A (IC4A) APC6). Do the Suction Belts turn properly? Is Suction Fan Motor M4 turning when the Start Key is pressed?

Result

Action Adjust the Solenoid, or check the Paper Separator Fingers for operation and clearance. Replace PWB-A. Correct or clean, or replace, the Paper Separator Fingers. Check the Actuator for operation. Check PC51. Replace PWB-A. Check the Actuator for operation. Check PC54. Check the Belts and Drive Gear. Check the DC24V line. Check M4.

10

YES

NO YES

11 D Paper is stationary before the Suction Belts.

12

NO YES NO

13

14

YES

YES

15

* Does the voltage across PJ6A-8 on PWB-A and GND change from DC24V to DC0V when the Start Key is pressed?

Replace PWB-A. NO

T-18

1158SBT030105A

1-5. Fusing/Exit Misfeed

Symbol PC53 PC54 M3 PWB-A Name Paper Exit Sensor Paper Leading Edge Detecting Sensor Suction Fan Motor Main Control Board

1158C02TAA

T-19

z Fusing/Exit Misfeed Clearing Procedure Symptom D Paper is stationary before the Fusing Roller. Step 1 Check Item Is the paper curled, waved, or damp? Is the Guide Plate dirty with toner? Do the Suction Belts turn properly? Is Suction Fan Motor M4 turning when the Start Key is pressed? 4 * Does the voltage across PJ6A-8 on PWB-A and GND change from DC24V to DC0V when the Start Key is pressed? Are the Fusing Rollers scratched or dirty? Or, has the replacement time arrived for the Rollers? Are the Paper Separator Fingers dirty with toner or worn? Are their edges damaged? Is the Oil Roller dirty? Or, has the replacement time arrived for the Roller? Check Paper Exit Sensor (PC53) See p. T-3. PC53: PWB-A (IC4A) APC5 Check Paper Leading Edge Detecting Sensor PC54 See p. T-3 (PWB-A (IC4A) APC6). Result YES Action Change the paper. Instruct the user in how to store the paper. Clean the Guide Plate. Check for possible scattering of toner. Check the Belts and Drive Gear. Check the DC24V line. Check M4. YES

YES

YES

Replace PWB-A. NO

D The leading edge of the paper is stationary near the Fusing Roller.

Clean or replace the Rollers. YES

YES

Clean or replace the Fingers.

Clean or replace the Roller. YES Check the Actuator for operation. Check PC53 or both. Replace PWB-A. Check the Actuator for operation. Check PC54.

7 D Paper is stationary after the Paper Exit Roller/Rolls.

NO YES NO

T-20

1151SBT0302A

2. Wrinkles in Paper
Step Cause Paper 1 Check Item Is the problem solved when new paper is used? Result Action Change the paper (that meets product specifications). Instruct the user in how to store the paper. Check the Drawer and Paper Take-Up Rolls and adjust, clean, and/or replace the parts as necessary. (See Skewed Feed that appears later.) Replace all Belts together or clean the Suction Deck. Clean the Guide Plate. YES Clean or replace the Thermistor. Move the Thermistor Mounting Bracket up or down as necessary so that the Thermistor comes in positive contact with the Upper Fusing Roller. Replace the Rollers. Replace the two Pressure Springs at once. YES

YES

Paper Take-Up Section 2

Is the paper taken up and fed in properly? NO

Transport Section Pre-Fusing Guide Plate Thermistor

Are any of the Belts slack or the Suction Deck dirty? Is the Guide Plate dirty with toner or other foreign matter? Is the Thermistor damaged or dirty with toner? Is the Thermistor in positive contact with the Upper Fusing Roller?

YES

YES

Fu using Unit

NO

Fusing Rollers Width of area of contact between the Upper and Lower Fusing Rollers

Has the Roller replacement time arrived? Does the location of wrinkles change when the position of the left and right Pressure Springs are changed?

YES

1158SBT0303A

3. Double Feed
Step Cause Paper 1 Paper Take-Up Section Check Item Is the problem solved when new paper is used? Result Action Change the paper (that is up to product specifications). Instruct the user in how to store the paper. Clean or replace the Paper Take-Up Roll. YES

YES

Paper Take-Up Roll

Is the Paper Take-Up Roll dirty, or has its replacement time arrived?

Paper Separator Roll

Is the Paper Separator Roll dirty?

YES

Clean or replace the Paper Separator Roll.

T-21

1158SBT0304A

4. Skewed Feed
Step Cause Paper 1 Check Item Is the problem solved when new paper is used? Result Action Change the paper (that is up to product specifications). Instruct the user in how to store the paper. Clean or replace the Paper Take-Up Roll. Change the locations of the Rolls according to the paper size being used Clean or replace the Paper Separator Roll. Clean the Paper Dust Remover and Upper Synchronizing Roller. Adjust the loop length in the Adjust Mode. Clean or replace the Transport Rollers. Adjust the loop length in the Adjust Mode. Clean or replace the Synchronizing Rollers. Replace the three Belts at once or clean the Suction Deck. Clean the Guide Plate.

YES

Paper Take-Up S Section

Paper Take-Up Roll

Is the Paper Take-Up Roll dirty, or has its replacement time arrived? Are the Paper Take-Up Rolls located correctly? (For the Copiers 1st Drawer)

YES

YES

Paper Separator Roll Paper Dust Remover Transport Rollers

Is the Paper Separator Roll dirty? Is the Paper Dust Remover dirty with paper dust? Are the Transport Rollers dirty or worn? Or Has their replacement time arrived? Are the Synchronizing Rollers dirty or worn? Or Has their replacement time arrived? Are any of the Belts left slack or the Suction Deck dirty? Is the Guide Plate dirty with toner or other foreign matter?

YES

YES

Transport Section t

YES

Synchronizing Rollers

YES

Suction Unit 7 Pre-Fusing Guide Plate

YES

YES

T-22

1151SBT0400A

4 MALFUNCTIONS
1158SBT0401A

1. Self-Diagnostic Function
The copier CPU is capable of self-diagnosis of the copier conditions and, when detecting a malfunction, it shows the corresponding malfunction code across the Zoom Ratio Indicator and Multi-Copy Display. Each malfunction code indicates the particular part which has developed a malfunction and the type of malfunction. A listing follows showing all malfunction codes and the description and possible causes of each malfunction.
Zoom Ratio Indicator Multi-Copy Display

X
Represents the detail of malfunction.

Indicates the particular malfunctioning unit of the greater physical unit. Indicates the malfunctioning physical unit.

* Copier/Paper Feed Cabinet (Option) Code C0000 Description Main Drive Motors failure to turn Main Drive Motor turning at abnormal timing PC Drive Motors failure to turn PC Drive Motor turning at abnormal timing Cooling Fan Motors failure to turn Toner Replenishing Motors failure to turn Toner Replenishing Motor turning at abnormal timing Possible Cause D Defective M2 D Defective PWB-A D Overloaded rolls/roller, gear, and belt D Defective M2 D Defective PWB-A D Defective M1 D Defective PWB-A D Overloaded gear D Defective M1 D Defective PWB-A D Defective M9 D Defective PWB-A D Defective Toner Hopper Position Sensor PC112 D Defective M8 D Defective PWB-A D Defective Toner Hopper Position Sensor PC112 D Defective M8 D Defective PWB-A

C0001 C0010

Drive

C0011 C004C C0070

C0711

T-23

* Copier/Paper Feed Cabinet (Option) Code Exposure Lamp C0400 Description Exposure Lamps failure to turn ON possible Cause D LA1 out D Blown Exposure Lamp Thermal Fuse TS2 D Defective AE Sensor D Defective PWB-A D Defective AE Sensor D Defective PWB-A D Defective Fusing Thermistor TH1 D Defective PWB-A D Defective Fusing Thermistor TH1 D Defective PWB-A D Defective PWB-A D Defective Power Supply Unit PU1 D Defective Power Supply Unit PU1 D Defective Fusing Thermal Fuse TF1 D Defective SSR D Defective Fusing Thermal Fuse TF1 D Defective SSR D Defective SSR

C4100 C0500

Exposure Lamp turning ON at abnormal timing Warming-up failure

Fusing Unit

D Fusing Heater Lamp H1 out C0510 Abnormally low fusing temperature

D Fusing Heater Lamp H1 out C0520 Abnormally high fusing temperature Scanner Motor malfunction D Defective Fusing Thermistor TH1 D Defective Scanner Motor M5 D Defective Scanner Reference Position Sensor PC81 D Defective Motor Drive Board PWB-E D Defective PWB-A D Defective Lens Motor M6 D Defective Lens Reference Position Sensor PC90 D Defective Motor Drive Board PWB-E D Defective PWB-A D Defective Mirror Motor M7 D Defective Mirror Reference Position Sensor PC86 D Defective Motor Drive Board PWB-E D Defective PWB-A D Defective AE Sensor Board PWB-H D Defective PWB-A D Exposure Lamp A1 out D Defective Power Supply Unit PU1

C0600

Optical Section

C0610

Lens Motor malfunction

C0620

Mirror Motor malfunction

C0F10 Sensors

Faulty AE Sensor level

C0F30

ATDC Sensor malfunction

D Defective ATDC Sensor UN3 D ATDC Sensor connection failure D Defective PWB-A

T-24

1151SBT040101A

1-1. C0000: Main Drive Motors failure to turn C0001: Main Drive Motor turning at abnormal timing
Symbol M2 PWB-A Name Main Drive Motor Main Control Board

1151C18TAA

T-25

Step 1 2

Check Item Is C0001 being shown? Does M2 start to turn when the Start Key is pressed? Does the voltage across PJ12A-10 on PWB-A and GND change from DC5V to DC0V when the Start Key is pressed? Does the voltage across PJ12A-9 on PWB-A and GND remain DC5V when the Start Key is pressed? Does the voltage across PJ12A-10 on PWB-A and GND remain DC0V when the Power Switch is turned ON? Does the voltage across PJ12A-9 on PWB-A and GND remain DC0V when the Power Switch is turned ON?

Result YES YES

Action Begin with step 5. Check rolls/rollers and gears for possible overload. Replace PWB-A.

NO

YES NO YES YES NO

Replace M2. Replace PWB-A. Replace PWB-A.

Replace M2. Replace PWB-A.

T-26

1151SBT040102A

1-2. C0010: PC Drive Motors failure to turn C0011: PC Drive Motor turning at abnormal timing
Symbol M1 PWB-A Name PC Drive Motor Main Control Board

1151C17TAA

T-27

Step 1 2

Check Item Is C0011 being shown? Does M1 start to turn when the Start Key is pressed? Does the voltage across PJ12A-8 on PWB-A and GND change from DC24V to DC0V when the Start Key is pressed? Does the voltage across PJ12A-7 on PWB-A and GND remain DC5V when the Start Key is pressed? Does the voltage across PJ12A-8 on PWB-A and GND remain DC0V when the Power Switch is turned ON? Does the voltage across PJ12A-7 on PWB-A and GND remain DC0V when the Power Switch is turned ON?

Result YES YES

Action Begin with step 5. Check gears for possible overload. Replace PWB-A.

NO

YES NO YES YES NO

Replace M1. Replace PWB-A. Replace PWB-A.

Replace M1. Replace PWB-A.

T-28

1151SBT040103A

1-3. C004C: Cooling Fan Motors failure to turn

Symbol M9 PWB-A Name Cooling Fan Motor Main Control Board

1151C16TAA

T-29

C004C Step 1 Check Item Is M9 turning at low speed when the Power Switch is in the ON position? Does the voltage across PJ6A-9 on PWB-A and GND change from DC12V to DC24V when the Start Key is pressed? Is the voltage across PJ6A-9 on PWBA and GND DC12V when the Power Switch is in the ON position? Result NO YES NO YES NO Action Begin with step 3. Replace M9. Replace PWB-A. Replace M9. Replace PWB-A.

T-30

1151SBT040104A

1-4. C0070: Toner Replenishing Motors failure to turn C0071: Toner Replenishing Motor turning at abnormal timing
Symbol PC112 M8 PWB-A Name Toner Hopper Home Position Sensor Toner Replenishing Motor Main Control Board

1151C09TAA

T-31

Step 1 2

Check Item Is C0071 being shown? Does the Toner Bottle turn when two or three copies are made with the Original Cover raised? Make two or three copies with the Original Cover raised. Does the voltage across PJ22A-10 on PWB-A and GND change to DC0V when the Toner Bottle is stopped and to DC5V when the Bottle is turned during the copy cycle? Make two or three copies with the Original Cover raised. Does the voltage across PJ6A-5 on PWB-A and GND change to DC0V when the Toner Bottle is stopped and to DC24V when the Bottle is turned during the copy cycle?

Result YES YES NO YES

Action Begin with step 3 Perform step 3. Perform step 4. Replace PWB-A. Check the Bottle Holder or PC112.

NO

YES

Replace M8. Replace PWB-A.

NO

T-32

1151SBT040105A

1-5. C0400: Exposure Lamps failure to turn ON C0410: Exposure Lamp turning ON at abnormal timing
Symbol LA1 TF2 PWB-A PWB-H PU1 Name Exposure Lamp Exposure Lamp Thermal Fuse Main Control Board AE Sensor Board Power Supply Unit

1151C03TAA

T-33

C0400 Step 1 Check Item Does LA1 light up when the Start Key is pressed? Does the voltage across PJ12A-11 on PWB-A and GND become DC4.3V or less when LA1 turns ON? Disconnect CN7 (2P). Is there continuity across CN7-1 and 2 on the LA1 side? Is the voltage across PJ2-1 and 2 on PU1 AC100V? Result YES Action Check the photo receiver of the AE Sensor for contamination. Replace PWB-H or PWB-A. Replace PWB-A. NO Check LA1 and TF2 for continuity. NO YES NO C0410 Step Check Item Does LA1 turn ON when the Power Switch is turned ON or in the standby state? Does the voltage across PJ12A-11 on PWB-A and GND remain DC4.3V or lower when the Power Switch is turned ON or in the standby state? Result Action Check to see if the photo receiver of the AE Sensor is receiving extraneous light. Replace PWB-H or PWB-A. Replace PWB-A. Replace PU1. Replace PU1. Check DC Power Supply Unit PU2 and Power Supply Board PWB-C.

NO

YES NO

T-34

1151SBT040106A

1-6. C0500: Warming-up failure C0510: Abnormally low fusing temperature C0520: Abnormally high fusing temperature
Symbol H1 TS1 TH1 PWB-A UN1 Name Fusing Heater Lamp Fusing Thermoswitch Fusing Thermistor Main Control Board SSR

1151C14TAA

T-35

C0500, C0510 * After resetting a C0510 condition, C0500 will be shown if the same problem recurs. For this reason, the same troubleshooting procedure is used for C0500 and C0510. Step 1 Check Item Does H1 light up when the Power Switch is turned ON? Disconnect CN14 (4P). Is the resistance across CN14-2 and 3 on the TH1 side infinity? Does the voltage across PJ3A-2 on PWB-A and GND change from DC4.5V to DC0V when the Front Door is closed with the Power Switch in the ON position? Disconnect CN5 (2P). Is there continuity across CN5-1 and 2 on the Fusing Unit side? Result YES NO YES NO Action Check TH1 for installation or clean it. Begin with step 3. Replace TH1. Replace PWB-A. Replace PWB-A. NO

YES NO

Replace UN1. Check H1 and TF1 for continuity.

C0520 Step A Check Item Does H1 remain lit up even after the copier has completed warming up? Does the voltage across PJ3A-2 on PWB-A and GND remain DC0V even after the copier has completed warming up? Disconnect CN14 (4P). Is the circuit across CN14-2 and 3 on the Fusing Unit side short-circuited? Result YES NO YES NO YES NO Action Begin with step B. Begin with step C. Replace PWB-A. Replace UN1. Replace TH1. Replace PWB-A.

T-36

1151SBT040107A

1-7. C0600: Scanner Motor malfunction C0610: Lens Motor malfunction C0620: Mirror Motor malfunction
Symbol M5 M6 M7 PC81 PC86 PC90 PWB-A PWB-E Name Scanner Motor Lens Motor Mirror Motor Scanner Reference Position Sensor Mirror Reference Position Sensor Lens Reference Position Sensor Main Control Board Motor Drive Board

1151C13TAA

T-37

C0600 Step 1 Check Item Does the Scanner start moving after the Power Switch has been turned ON? Does the voltage across PJ16A-3 on PWB-A and GND change from DC5V to DC0V after the Power Switch has been turned ON? Check Scanner Reference Position Sensor PC81. See p. T-3 (PWB-A (IC4A) APB0) Result YES YES NO Perform step 3. Replace PWB-E or M5. Replace PWB-A. Check the Scanner Drive Cable for tension and overload. Or, replace PWB-A. Check PC81. Action

YES NO

C0610 Step A Check Item Does M6 start turning after the Power Switch has been turned ON? Does the voltage across PJ16A-1 on PWB-A and GND change from DC5V to DC0V after the Power Switch has been turned ON? Is the voltage across PJ3E-5 on PWB-E and GND DC24V after the Power Switch has been turned ON? Check Lens Reference Position PC90. See p. T-3 (PWB-A (IC4A) APB1) Result YES Perform step D. Replace PWB-A. NO Action

YES NO YES NO

Replace PWB-E or M6. Check the 24V line. Check the Lens Drive Cable for tension and overload. Or, replace PWB-A. Check PC90.

C0620 Step I II Check Item Does M7 start turning? Does the voltage across PJ16A-2 on PWB-A and GND change from DC5V to DC0V when the Mirror moves? Check Mirror Reference Position PC86. See p. T-3 (PWB-A (IC4A) APB2) Result YES YES NO YES NO Perform step III. Replace PWB-E or M7. Replace PWB-A. Check for overload. Or, replace PWB-A. Check PC86. Action

III

T-38

1158SBT040084A

1-8. C0F10: Faulty AE Sensor level C0F30: ATDC Sensor malfunction

Symbol PWB-A PWB-H UN3 Name Main Control Board AE Sensor Board ATDC Sensor

1151C10TAA

T-39

C0F10 Step Check Item Is the voltage across PJ12A-3 on PWB-A and GND in the range between DC2V and DC4V when the Start Key is pressed in the F3 operation? Result YES NO Action Replace PWB-A. Check the photo receiver of the AE Sensor for contamination or replace PWB-H.

C0F30 Step A Check Item Is the voltage across PJ1A-3 on PWB-A and GND DC0V after the Power Switch has been turned ON? Is the voltage across PJ1A-3 on PWB-A and GND in the range between DC0.5V and DC4.5V after the Start Key has been pressed? Result YES Action Check the ATDC Sensor and the connection between the Imaging Unit and copier. Replace PWB-A. Replace the ATDC Sensor.

YES NO

T-40

1158SBT040109A

1-9. C0F02: Original size detection error (Defective CPU) C0FE2 to C0FFF: Original Size Detecting Sensor failure
Symbol PC113 PC114 PC115 PC116 UN2 PWB-A Name Original Size Detecting Sensor FD2 Original Size Detecting Sensor CD1 Original Size Detecting Sensor FD3 Original Size Detecting Sensor CD2 Original Size Detecting Board Master Board

1151C09TAA

T-41

Step 1

Check Item Is any code from among C0FE2 to C0FFF being shown? Are jumper straps installed in the following position for J1 and J2 of UN2? J1: On the end not marked with O J2: On the end not marked with O Does the LED of I/O port check PWB-A (IC5A) PA3 blink after the Power Switch has been turned ON? Is the Sensor located at the correct position? Does the problem persist even after the corresponding Sensor has been replaced?

Result YES Perform step 4.

Action

Change the strap position of J1 and J2. NO

YES NO NO

Replace PWB-A. Replace UN2. Change the position of the Sensor. Replace UN2 or PWB-A.

YES

T-42

1151SBT0402A

2. Power is not Turned ON

Symbol PWB-A PWB-C PU2 S1 S21 RY1 Name Master Board Power Supply Board DC Power Supply Unit Power Switch Front Door Interlock Switch Main Relay

T-43

Symptom Power is not supplied to the copier at all.

Step

Check Item Is the source voltage being supplied to the circuit across PJ1-1 and 3 of PU2? Is the voltage across PJ3-1 of PU2 and GND, and across PJ3-3 on PU2 and GND, DC24V? Is the voltage across PJ1C-3 on PWB-C and GND, and across PJ1C-5 on PWB-C and GND, DC24V? Is LD1 on PWB-A lit up? Is the voltage across PJ1C-3 on PWB-C and GND DC24V? Is the voltage across PJ1A-14 on PWB-A and GND, and across PJ1A-15 on PWB-A and GND, near DC0V? Is the voltage across PJ1C-2 on PWB-C and GND DC24V after the Power Switch has been turned ON? Is the voltage across PJ1C-1 on PWB-C and GND DC0V after the Power Switch has been turned ON?

Result

Action Check Fuse or line voltage.

NO

NO

Check Fuse of PU2 or replace PU2.

Check S1 and S21. NO

4 Only the control panel Indicators light up. RY1 is not energized.

NO

Check Fuse of PWB-C or replace PWB-C. Check S21.

NO Replace PWB-A. NO

Replace PWB-C. NO

Check RY1. NO

* If the problem persists even after the above procedures, the harness is probably short-circuited. Check the harnesses.

T-44

1151SBT0403A

3. E1, E2
Symbol UN3 F4 PWB-A ATDC Sensor I/U Fuse Master Board Name

1151C07TAA

T-45

Code

Step 1

Check Item Is the seal peeled off the opening or starter been fully charged? Is the voltage across PJ1A-3 on PWB-A and GND in the range between DC0.5V and DC4.5V after the Start Key has been turned ON? Is the voltage across PJ1A-6 on PWB-A and GND 0V (is F4 blown)?

Result NO YES

Action Peel off the seal and turn the Power Switch OFF, then ON. Replace PWB-A.

E1 2

NO YES NO

Replace the ATDC Sensor.

Replace PWB-A. Replace F4 or PWB-A.

E2

T-46